Floor coverings and floor covering systems and methods of making and installing same

ABSTRACT

Floor coverings having a greige good, an adhesive layer, and a secondary backing material. The greige good has a primary backing component having adjoined first and second portions, and a plurality of fibers. The secondary backing material has an attached portion and a first exposable portion, with the attached portion adhered to the first portion of the primary backing component by contact with the adhesive layer. The second portion of the primary backing component is unattached to the first exposable portion of the secondary backing material, and the first exposable portion defines a portion of the first end edge of the floor covering. The second portion of the primary backing component is selectively moveable relative to the first portion to a position in which at least a portion of the second portion of the primary backing component does not overlie the first exposable portion of the secondary backing material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/946,320, filed on Apr. 5, 2018, which claims priority to and thebenefit of the filing date of U.S. Provisional Patent Application No.62/481,943, which was filed on Apr. 5, 2017. Each of these earlier-filedapplications is hereby incorporated by reference herein in its entirety.

FIELD

The present invention relates to floor coverings and floor coveringsystems having improved seaming capabilities for ease of welding andinstallation and to provide an impermeable barrier to fluid penetration.

BACKGROUND

Conventional floor coverings and floor covering systems havehistorically been manufactured to include a fully attached membranecomposite. For example, floor coverings typically include a membranecomposite having a primary backing component and a secondary backingmaterial that can be adhered to the primary backing component across thefull length of the floor covering. Attached to the primary backingcomponent is typically a plurality of fibers extending from its facesurface. The installation of floor coverings generally includesunrolling the floor covering material, cutting the material to thedesired sizes, and adjoining adjacent floor covering materials by somemanner and means. Various installation techniques have been utilized foradjoining adjacent floor coverings, including, for example, byoverlapping an edge of a first floor covering with an edge of a secondfloor covering such that the first floor covering overlies the secondfloor covering. Once overlapped, a heat welding process can be employedto form a bond between the two floor coverings. However, these methodsinvolve seaming of an attached membrane composite, which can createinstallation challenges and impede market acceptance. Typically, fibersbecome trapped in the overlapped region of adjoined floor coverings,resulting in an undesirable aesthetic appearance. Moreover, seaming ofattached membrane composites often leads to problems with fluidpenetration at the overlapped region.

SUMMARY

Described herein, in various aspects, are floor coverings having opposedfirst and second side edges and opposed first and second end edgesextending between and oriented perpendicularly to the first and secondside edges, the floor covering having a width corresponding to adistance between the first and second side edges and a lengthcorresponding to a distance between the first and second end edges. Thefloor covering described herein comprises a greige good, an adhesivelayer, and a secondary backing material. The greige good comprises aprimary backing component defining a face surface and an opposed backsurface and having a first portion and a second portion adjoining thefirst portion. The first and second portions of the primary backingcomponent extend along respective portions of the length of the floorcovering. The greige good further comprises a plurality of fibersattached to the primary backing component and extending from the facesurface of the primary backing component. The adhesive layer includes afirst surface and an opposed second surface and comprises an adhesivecomposition. The first surface of the adhesive layer is applied to theback surface of the first and second portions of the primary backingcomponent. The secondary backing material comprises an attached portionand at least a first exposable portion. The attached portion is adheredto the first portion of the primary backing component by contact withthe second surface of the adhesive layer. The second portion of theprimary backing component is unattached to the first exposable portionof the secondary backing material. The first exposable portion defines aportion of the first end edge of the floor covering. The second portionof the primary backing component is selectively moveable relative to thefirst portion of the primary backing component to a position in which atleast a portion of the second portion of the primary backing componentdoes not overlie the first exposable portion of the secondary backingmaterial. Also described herein are floor covering systems comprisingthe disclosed floor coverings, as well as methods of making andinstalling the disclosed floor coverings.

Additional advantages of the invention will be set forth in part in thedescription which follows, and in part will be obvious from thedescription, or may be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

DESCRIPTION OF THE DRAWINGS

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 shows a cross-sectional side view of an exemplary floor coveringhaving a moveable body as disclosed herein.

FIG. 2 shows a cross-sectional side view of another exemplary floorcovering having first and second moveable bodies as disclosed herein.

FIG. 3 shows a cross-sectional side view of an exemplary floor coveringsystem including two floor coverings positioned adjacent to one another,with exposed portions of the secondary backing materials overlapping oneanother.

FIG. 4 shows a schematic illustration of an exemplary system and methodfor making a floor covering as disclosed herein.

FIGS. 5A-5E show the sequential positioning and installation of anexemplary floor covering system 200 as disclosed herein. FIG. 5A showsexemplary first and second floor coverings positioned adjacent to oneanother, each having a moveable body in the closed position as disclosedherein. FIG. 5B shows the exemplary first and second floor coveringswith each moveable body in the open position as disclosed herein. FIG.5C shows the exemplary first and second floor coverings, each having asecondary backing material with an exposable portion as disclosedherein. FIG. 5C further shows overlapping of the exposable portions ofthe exemplary first and second floor coverings as disclosed herein. FIG.5D shows the overlapped region of the secondary backing materials of theexemplary first and second floor coverings heat welded, forming acontinuous barrier as disclosed herein. FIG. 5E shows the exemplaryfirst and second floor coverings, with each moveable body moved to theclosed position following application of heat as disclosed herein. Asfurther disclosed herein, after positioning of the moveable bodies inthe closed position, the moveable bodies can be welded or otherwisesecured together.

FIG. 6 is a top view of an exemplary floor covering 100 having first andsecond side edges, first and second end edges, and a length and a widthas disclosed herein.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentcompositions, articles, devices, systems, and/or methods are disclosedand described, it is to be understood that this invention is not limitedto the specific compositions, articles, devices, systems, and/or methodsdisclosed unless otherwise specified, as such can, of course, vary. Itis also to be understood that the terminology used herein is for thepurpose of describing particular aspects only and is not intended to belimiting.

The following description of the invention is also provided as anenabling teaching of the invention in its best, currently known aspect.To this end, those of ordinary skill in the relevant art will recognizeand appreciate that changes and modifications can be made to the variousaspects of the invention described herein, while still obtaining thebeneficial results of the present invention. It will also be apparentthat some of the desired benefits of the present invention can beobtained by selecting some of the features of the present inventionwithout utilizing other features. Accordingly, those of ordinary skillin the relevant art will recognize that many modifications andadaptations to the present invention are possible and can even bedesirable in certain circumstances and are thus also a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

In the following description, numerous specific details are set forth inorder to provide a thorough understanding described herein. It will beobvious, however, to one skilled in the art that the present disclosuremay be practiced without these specific details. In other instances,well-known aspects of carpet manufacture and artificial turf have notbeen described in particular detail in order to avoid unnecessarilyobscuring aspects of the disclosed implementations.

Various combinations of elements of this disclosure are encompassed bythis invention, e.g. combinations of elements from dependent claims thatdepend upon the same independent claim.

Moreover, it is to be understood that unless otherwise expressly stated,it is in no way intended that any method set forth herein be construedas requiring that its steps be performed in a specific order.Accordingly, where a method claim does not actually recite an order tobe followed by its steps or it is not otherwise specifically stated inthe claims or descriptions that the steps are to be limited to aspecific order, it is no way intended that an order be inferred, in anyrespect. This holds for any possible non-express basis forinterpretation, including: matters of logic with respect to arrangementof steps or operational flow; plain meaning derived from grammaticalorganization or punctuation; and the number or type of aspects describedin the specification.

All publications mentioned herein are incorporated herein by referenceto disclose and describe the methods and/or materials in connection withwhich the publications are cited.

It is also to be understood that the terminology used herein is for thepurpose of describing particular aspects only and is not intended to belimiting. As used in the specification and in the claims, the term“comprising” may include the aspects “consisting of” and “consistingessentially of.” Unless defined otherwise, all technical and scientificterms used herein have the same meaning as commonly understood by one ofordinary skill in the art to which this invention belongs. In thisspecification and in the claims which follow, reference will be made toa number of terms which shall be defined herein.

As used herein, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, reference to a “secondary backing material” includes aspectshaving two or more secondary backing materials unless the contextclearly indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint. It is also understood that there are a number of valuesdisclosed herein, and that each value is also herein disclosed as“about” that particular value in addition to the value itself. Forexample, if the value “10” is disclosed, then “about 10” is alsodisclosed. It is also understood that each unit between two particularunits are also disclosed. For example, if 10 and 15 are disclosed, then11, 12, 13, and 14 are also disclosed.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

As used herein, the terms “floor covering” and “carpet” are usedinterchangeably, and in the manner as would be recognized by one ofordinary skill in the art. The definition of floor covering and carpet,as used herein, includes any floor coverings, carpets, or carpetproducts known in the art. For example and without limitation, the terms“floor covering” and “carpet” include carpet tiles, rugs, turfs. As anexample, and without limitation, the terms “floor covering” and “carpettile” include tiles formed from broadloom textile flooring products thatare provided in roll form.

As used herein, the term “by weight,” when used in conjunction with acomponent, unless specially stated to the contrary is based on the totalweight of the formulation or composition in which the component isincluded. For example, if a particular element or component in acomposition or article is said to have 8% by weight, it is understoodthat this percentage is in relation to a total compositional percentageof 100%.

A weight percent of a component, or weight %, or wt. %, unlessspecifically stated to the contrary, is based on the total weight of theformulation or composition in which the component is included.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition or article,denotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a composition or a selectedportion of a composition containing 2 parts by weight of component X and5 parts by weight component Y, X and Y are present at a weight ratio of2:5, and are present in such ratio regardless of whether additionalcomponents are contained in the composition.

As used herein, the term “substantially,” in, for example, the context“substantially free” refers to a composition having less than about 1%by weight, e.g., less than about 0.5% by weight, less than about 0.1% byweight, less than about 0.05% by weight, or less than about 0.01% byweight of the stated material, based on the total weight of thecomposition.

It is further understood that the term “substantially,” when used inreference to a composition, refers to at least about 60% by weight,e.g., at least about 65%, at least about 70%, at least about 75%, atleast about 80%, at least about 85%, at least about 90%, at least about91%, at least about 92%, at least about 93%, at least about 94%, atleast about 95%, at least about 96%, at least about 97%, at least about98%, at least about 99%, or about 100% by weight, based on the totalweight of the composition, of a specified feature or component.

As used herein, the term “substantially,” in, for example, the context“substantially identical reference composition,” refers to a referencecomposition comprising substantially identical components in the absenceof an inventive component. In another exemplary aspect, the term“substantially,” in, for example, the context “substantially identicalreference composition,” refers to a reference composition comprisingsubstantially identical components and wherein an inventive component issubstituted with a common in the art component. For example, asubstantially identical reference carpet composition can comprise asubstantially identical plurality of reference fibers attached to thereference primary backing material and extending the face of thereference primary backing material and exposed at the back side of thereference primary backing material, a reference precoat compositioncomprising latex, and wherein a thermoplastic dispersion is absent fromthe precoat composition; and a substantially identical referencesecondary backing material applied to a back surface of the referenceprecoat layer; and a substantially identical polymer film.

As used herein, the term “substantially,” in, for example, the context“substantially similar wet and dry delamination strength,” refers tovalues of wet delamination strength that are different from values ofdry delamination strength by about 30% or less, by about 20% or less, byabout 10% or less, by about 5% or less, by about 1% or less, or by about0.5% or less.

The term “fiber” as used herein includes fibers of extreme or indefinitelength (i.e. filaments) and fibers of short length (i.e., staplefibers).

The term “yarn” as used herein refers to a continuous strand, length, orbundle of fibers. The fibers can be any type of fiber as describedherein.

As used herein, the term “copolymer” refers to a polymer formed from twoor more different repeating units (monomer residues). By way of exampleand without limitation, a copolymer can be an alternating copolymer, arandom copolymer, a block copolymer, or a graft copolymer.

The term “linear” as used to describe ethylene polymers is used hereinto mean the polymer backbone of the ethylene polymer lacks measurable ordemonstrable long chain branches, e.g., the polymer is substituted withan average of less than 0.01 long branch/1000 carbons.

The term “homogeneous ethylene polymer” as used to describe ethylenepolymers is used in the conventional sense in accordance with theoriginal disclosure by Elston in U.S. Pat. No. 3,645,992, the disclosureof which is incorporated herein by reference. As defined herein,homogeneous ethylene polymers include both substantially linear ethylenepolymers and homogeneously branched linear ethylene.

Homogeneously branched ethylene polymer is homogeneous ethylene polymerthat refers to an ethylene polymer in which the monomer or comonomer israndomly distributed within a given polymer or interpolymer molecule andwherein substantially all of the polymer or interpolymer molecules havesubstantially the same ethylene to comonomer molar ratio with thatpolymer or interpolymer.

Alternatively, homogeneously branched ethylene polymers can be definedas homogeneous ethylene polymers that possess short chain branches andcharacterized by a relatively high short chain branching distributionindex (SCBDI) or relatively high composition distribution branchingindex (CDBI). That is, the ethylene polymer has a SCBDI or CDBI greaterthan or equal to 50 percent, greater than or equal to 70 percent, orgreater than or equal to 90 percent and essentially lack a measurablehigh density (crystalline) polymer fraction.

In the aspects wherein the homogeneously branched ethylene polymers arecharacterized by the short chain branching distribution index orcomposition distribution branching index, the SCBDI or CDBI can bedefined as the weight percent of the polymer molecules having acomonomer content within 50 percent of the median total molar comonomercontent and represents a comparison of the comonomer distribution in thepolymer to the comonomer distribution expected for a Bernoulliandistribution. The SCBDI or CDBI of polyolefins can be convenientlycalculated from data obtained from techniques known in the art, such as,for example, temperature rising elution fractionation (abbreviatedherein as “TREF”) as described, for example, by Wild et al., Journal ofPolymer Science, Poly. Phys. Ed., Vol. 20, p. 441 (1982), L. D. Cady,“The Role of Comonomer Type and Distribution in LLDPE ProductPerformance,” SPE Regional Technical Conference, Quaker Square Hilton,Akron, Ohio, October 1-2, pp. 107-119 (1985), or in U.S. Pat. Nos.4,798,081 and 5,008,204, the disclosures of all of which areincorporated herein by reference. In some aspects, the comonomerdistribution of the polymer and SCBDI or CDBI are determined using¹³CNMR analysis in accordance with techniques described, for example, inU.S. Pat. No. 5,292,845 and by J. C Randall in Rev. Macromol. Chem.Phys., C29, pp. 201-317, the disclosures of which are incorporatedherein by reference.

In some aspects, the terms “homogeneously branched linear ethylenepolymer” and “homogeneously branched linear ethylene/α-olefin polymer”means that the olefin polymer has a homogeneous or narrow shortbranching distribution but does not have long chain branching. That is,the linear ethylene polymer is a homogeneous ethylene polymercharacterized by an absence of long chain branching. Such polymers canbe made using polymerization processes (e.g., as described by Elston inU.S. Pat. No. 3,645,992) which provide a uniform short chain branchingdistribution (i.e., homogeneously branched). Homogeneously branchedlinear ethylene polymers are typically characterized as having amolecular weight distribution, M_(w)/M_(n), of less than about 3, lessthan about 2.8, or less than about 2.3. Commercial examples of suitablehomogeneously branched linear ethylene polymers include those sold byMitsui Petrochemical Industries as Tafmer™ resins and by Exxon ChemicalCompany as Exact™ resins and Exceed™ resins. Alternatively, the terms“homogeneously branched linear ethylene polymer” and “homogeneouslybranched linear ethylene/α-olefin polymer” means that the olefin polymerhas a relatively high SCBDI or CDBI.

The terms “homogeneous linearly branched ethylene polymer” or“homogeneously branched linear ethylene/α-olefin polymer” do not referto high pressure branched polyethylene which is known to those skilledin the art to have numerous long chain branches. The term “homogeneouslinear ethylene polymer” generically refers to both linear ethylenehomopolymers and to linear ethylene/α-olefin interpolymers. A linearethylene/α-olefin interpolymer possesses short chain branching and theα-olefin is typically at least one C₃-C₂₀ α-olefin (e.g., propylene,1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, and 1-octene). Inother aspects the polyethylenes that are suitable for use in the presentinvention are interpolymers of ethylene with at least one C₃-C₂₀α-olefin and/or C₄-C₁₈ diolefin. Copolymers of ethylene and α-olefin ofC₃-C₂₀ carbon atoms can be used.

The term “interpolymer” is used herein to indicate a copolymer, or aterpolymer, or the like, where at least one other comonomer ispolymerized with ethylene to make the interpolymer. Suitable unsaturatedcomonomers useful for polymerizing with ethylene include, for example,ethylenically unsaturated monomers, conjugated or non-conjugated dienes,polyenes, etc. Examples of such comonomers include C₃-C₂₀ α-olefins aspropylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene,1-heptene, 1-octene, 1-nonene, 1-decene, 1,9-decadiene and the like.Other suitable monomers include styrene, halo- or alkyl-substitutedstyrenes, tetrafluoroethylene, vinylbenzocyclobutane, 1,4-hexadiene,1,7-octadiene, and cycloalkenes, e.g., cyclopentene, cyclohexene andcyclooctene.

When used in reference to an ethylene homopolymer (i.e., a high densityethylene polymer not containing any comonomer and thus no short chainbranches), the term “homogeneous ethylene polymer” or “homogeneouslinear ethylene polymer” means the polymer was made using a homogeneouscatalyst system such as, for example, that described Elston or Ewen orthose described by Canich in U.S. Pat. Nos. 5,026,798 and 5,055,438, orby Stevens et al. in U.S. Pat. No. 5,064,802, the disclosures of allthree of which are incorporated herein by reference.

The terms “substantially linear ethylene polymer” or “SLEP,” are usedinterchangeably, and refer specifically to homogeneously branchedethylene polymers that have long chain branching. The term does notrefer to heterogeneously or homogeneously branched ethylene polymersthat have a linear polymer backbone. For substantially linear ethylenepolymers, the long chain branches have the same comonomer distributionas the polymer backbone, and the long chain branches can be as long asabout the same length as the length of the polymer backbone to whichthey are attached. The polymer backbone of substantially linear ethylenepolymers is substituted with about 0.01 long chain branches/1000 carbonsto about 3 long chain branches/1000 carbons, from about 0.01 long chainbranches/1000 carbons to about 1 long chain branches/1000 carbons, andfrom about 0.05 long chain branches/1000 carbons to about 1 long chainbranches/1000 carbons.

Long chain branching is defined herein as a chain length of at least 6carbons, above which the length cannot be distinguished using ¹³Cnuclear magnetic resonance spectroscopy. The presence of long chainbranching can be determined in ethylene homopolymers by using ¹³Cnuclear magnetic resonance (NMR) spectroscopy and is quantified usingthe method described by Randall (Rev. Macromol. Chem. Phys., C29, V.2&3, p. 285-297), the disclosure of which is incorporated herein byreference.

Substantially linear ethylene polymers are homogeneously branchedethylene polymers and are disclosed in U.S. Pat. Nos. 5,272,236 and5,278,272, the disclosures of which are incorporated herein byreference. Homogeneously branched substantially linear ethylene polymersare available from The Dow Chemical Company as AFFINITY™ polyolefinplastomers and from Dupont Dow Elastomers JV as ENGAGE™ polyolefinelastomers. Homogeneously branched substantially linear ethylenepolymers can be prepared via the solution, slurry, or gas phasepolymerization of ethylene and one or more optional α-olefin comonomersin the presence of a constrained geometry catalyst, such as the methoddisclosed in European Patent Application 416,815-A, the disclosure ofwhich is incorporated herein by reference. In some aspects, a solutionpolymerization process is used to manufacture the substantially linearethylene polymer used in the present invention.

The term “heterogeneously branched ethylene polymer” refers to a polymerhaving a distribution of branching different from and broader that thehomogeneous branching ethylene/α-olefin interpolymer at similarmolecular weight. In further aspects, the “heterogeneous” and“heterogeneously branched” mean that the ethylene polymer ischaracterized as a mixture of interpolymer molecules having variousethylene to comonomer molar ratios. Alternatively, heterogeneouslybranched linear ethylene polymers can be defined as having a SCBDI lessthan about 50% and more typically less than about 30%. HBEPs and SLEPsalso differ from the class of polymers known conventionally asheterogeneously branched traditional Ziegler polymerized linear ethyleneinterpolymers, for example, ultra-low density polyethylene (“ULDPE”),very low density polyethylene (“VLDPE”), linear low density polyethylene(“LLDPE”) medium density polyethylene (“MDPE”) or high densitypolyethylene (“HDPE”) made, for example, using the technique disclosedby Anderson et al. in U.S. Pat. No. 4,076,698, in that substantiallylinear ethylene interpolymers are homogeneously branched interpolymers.Further, in accordance with the present invention, the polymercomposition does not comprise more than 20% by weight of heterogeneouslybranched linear ethylene polymers, as measured by the total weight ofthe polymer composition.

Heterogeneously branched ethylene polymers are typically characterizedas having molecular weight distributions, M_(w)/M_(n) in the range offrom about 3.5 to about 4.1 and, as such, are distinct fromsubstantially linear ethylene polymers and homogeneously branched linearethylene polymers in regards to both compositional short chain branchingdistribution and molecular weight distribution.

The substantially linear ethylene polymers useful in this invention haveexcellent processability, even though they have relatively narrowmolecular weight distributions (MWDs). Furthermore, the melt flow ratio(I₁₀/I₂) of the substantially linear ethylene polymers can be variedessentially independently of the polydispersity index (i.e., molecularweight distribution (M_(w)/M_(n))). This is contrasted with conventionalheterogeneously branched linear polyethylene resins which haverheological properties such that as the polydispersity index increases,the I₁₀/I₂ value also increases. The rheological properties ofsubstantially linear ethylene polymers also differ from homogeneouslybranched linear ethylene polymers which have relatively low, essentiallyfixed I₁₀/I₂ ratios.

HBEPs and SLEPs also differ significantly from the class known asfree-radical initiated highly branched high pressure low densityethylene homopolymer and ethylene interpolymers such as, for example,ethylene-acrylic acid (EAA) copolymers and ethylene-vinyl acetate (EVA)copolymers, in that substantially linear ethylene polymers do not haveequivalent degrees of long chain branching and are made using singlesite catalyst systems rather than free-radical peroxide catalystsystems. In accordance with the present invention, the polymercomposition does not comprise more than 20% by weight of free-radicalinitiated highly branched high pressure low density ethylene homopolymerand ethylene interpolymers, as measured by the total weight of thepolymer composition, exclusive of any adhesive polymer that containssuch homopolymers and interpolymers (as discussed in more detail below).

In some aspects of the present invention, certain component parts of thedisclosed floor coverings are characterized as including woven materialsor woven textile. It should be understood that in some aspects woventextiles have the appearance of two-sets of parallel threads or yarnsinterlaced at generally right angles to each other in the plane of thefabric. “Warp” yarns or threads lie along the length of the fabric and“weft” yarns lie in the transverse direction, i.e. across the width ofthe fabric. The type of yarns used to produce a woven textile caninclude, without limitation, monofilament, multifilament, a combinationof monofilament and multifilament, spun yarns, tape or slit film yarns,or a combination of tape and spun yarns. In some aspects of theinvention, the term “tape-spun” yarn refers to yarn having a slit filmyarn in the warp direction and spun (relatively short staple length)yarn in the weft direction. In other aspects of the invention, the term“tape-tape” yarn refers to yarn having a slit film yarn both in the warpand the weft directions.

As described herein, the term “impermeable” refers to materials that donot allow the disclosed substances to pass through it. For example, andwithout limitation, a fluid impermeable material can be impermeable toboth liquids and gases.

As described herein, the term “semipermeable” refers to materials thatdo not allow certain substances to permeate but do allow certain otherspecified materials to pass through it. For example, and withoutlimitation, a semipermeable fluid barrier can be permeable to gases andimpermeable to liquids, or vice versa.

While aspects of the present invention can be described and claimed in aparticular statutory class, such as the system statutory class, this isfor convenience only and one of skill in the art will understand thateach aspect of the present invention can be described and claimed in anystatutory class. Unless otherwise expressly stated, it is in no wayintended that any method or aspect set forth herein be construed asrequiring that its steps be performed in a specific order. Accordingly,where a method claim does not specifically state in the claims ordescriptions that the steps are to be limited to a specific order, it isno way intended that an order be inferred, in any respect. This holdsfor any possible non-express basis for interpretation, including mattersof logic with respect to arrangement of steps or operational flow, plainmeaning derived from grammatical organization or punctuation, or thenumber or type of aspects described in the specification.

A. Floor Coverings

As summarized above and with reference to FIGS. 1-6 , aspects of theinvention disclosed herein provide a floor covering 100 having opposedfirst and second side edges 102, 104 and opposed first and second endedges 106, 108 extending between and oriented perpendicularly to thefirst and second side edges. In these aspects, it is contemplated thatthe floor covering 100 can have a width 110 corresponding to a distancebetween the first and second side edges 102, 104 and a length 112corresponding to a distance between the first and second end edges 106,108. In further aspects, the floor covering 100 can comprise a greigegood 114, an adhesive layer 132, and a secondary backing material 150.The greige good 114 can comprise a primary backing component 116, whichcan have a face surface 118 and an opposed back surface 120. The primarybacking component 116 also can have a first portion and a second portion122, 124 adjoining the first portion. The first and second portions ofthe primary backing component 116 can extend along respective portionsof the length 112 of the floor covering 100. In exemplary aspects, it iscontemplated that the floor covering 100 can comprise two primarybacking components or layers 116, with the back surface 120 of a primarybacking component abutting the face surface 118 of another primarybacking component. In exemplary aspects, it is further contemplated thatthe floor covering 100 can comprise a plurality of primary backingcomponents or layers that are positioned in a stacked configuration.Optionally, the plurality of primary backing materials can be stackedwithout the need for adhesive layers between the respective primarybacking materials. The greige good 114 can further comprise a pluralityof fibers 128 attached to the primary backing component 116 andextending from the face surface 118 of the primary backing component116. In additional aspects, the adhesive layer 132 can have a firstsurface 134 and an opposed second surface 136. In these aspects, theadhesive layer 132 can comprise an adhesive composition 138. The firstsurface 134 of the adhesive layer 132 can be applied to the back surface120 of the first and second portions 122, 124 of the primary backingcomponent 116. As shown in FIG. 1 , the portion of the adhesive layer132 applied to the second portion 124 of the primary backing component116 and the second portion 124 of the primary backing component 116 cancooperate to define a moveable body 140. Optionally, it is contemplatedthat the moveable body 140 can be provided as a flap. In furtheraspects, the secondary backing material 150 can have an attached portion152 and at least a first exposable portion 154. In these aspects, theattached portion 152 can be adhered (coupled) to the first portion 122of the primary backing component 116 by contact with the second surface136 of the adhesive layer 132 underlying the first portion 122 of theprimary backing component 116. In these aspects, the moveable body canbe unattached to the first exposable portion 154 of the secondarybacking material 150. The first exposable portion 154 can define aportion of the first end edge 106 of the floor covering 100. It iscontemplated that the moveable body 140 can be selectively moveablerelative to the first portion 122 of the primary backing component 116to a position in which at least a portion of the second surface 136 ofthe adhesive layer 132 of the moveable body 140 can be vertically spacedfrom the first exposable portion 154 of the secondary backing material150. Optionally, it is contemplated that the secondary backing material150 can comprise a multi-layer secondary backing material. Optionally,it is further contemplated that the floor covering 100 can comprise aplurality of secondary backing materials 150 (i.e., multiple, stackedsecondary backing materials). Optionally, when a plurality of secondarybacking materials is provided, it is contemplated that additionaladhesive layers can be provided between sequential secondary backingmaterials. However, such adhesive layers are not required and can beomitted when appropriate.

As further described herein, it is contemplated that the floor covering100 can further comprise a sealing material 160 disposed onto the secondsurface 136 of the adhesive layer 132 of the moveable body 140. In theseaspects, the sealing material 160 can be configured to create a barrierbetween the adhesive layer 132 of the moveable body 140 and the firstexposable portion 154 of the secondary backing material 150. It iscontemplated that the sealing material 160 can be any material that canencapsulate the adhesive layer 132 of the moveable body 140 and preventthe moveable body from adhering to the exposable portion 154 of thesecondary backing material 150. For example and without limitation, thesealing material 160 can comprise a polyethylene film, as furtherdescribed herein.

In exemplary aspects, it is contemplated that the moveable body can beconfigured for selective pivotal movement relative to the first portion122 of the primary backing component 116 such that the moveable body 140can be moveable about and between a closed position and an openposition. In the closed position, the moveable body can overlie thefirst exposable portion 154 of the secondary backing material 150 andcooperate with the first exposable portion 154 to define the first endedge 106 of the floor covering 100. In these aspects, the moveable body140 can be configured to pivot about a pivot axis 162 defined at anintersection 164 between the first and second portions 122, 124 of theprimary backing component 116 such that the moveable body 140 can bemoveable between the closed position and the open position. It iscontemplated that the pivot axis 162 can be perpendicular orsubstantially perpendicular to a longitudinal axis 166 of the floorcovering 100 extending from the first end edge 106 to the second endedge 108. In the open position, the second portion 124 of the primarybacking component 116 can be advanced (e.g., folded) inwardly toward thefirst portion 122 of the primary backing component 116. In the openposition, at least a portion of the second surface 136 of the adhesivelayer 132 of the moveable body 140 can be vertically spaced from thefirst exposable portion 154 of the secondary backing material 150 asfurther disclosed herein. Optionally, in the open position, the moveablebody 140 can be advanced (e.g., folded) inwardly such that a portion ofthe adhesive layer 132 of the moveable body overlies the attachedportion 152 of the secondary backing material 150 (and does not overliethe first exposable portion 154). The pivot axis 162 can be spaced fromthe first end edge 106 by a selected distance corresponding to a lengthof the moveable body. In these aspects, it is contemplated that theselected distance can range from about 1 inch to about 25 inches. Moreparticularly, the selected distance can range from about 5 inches toabout 20 inches, or from about 6 inches to about 18 inches.

In further exemplary aspects and with reference to FIG. 2 , the primarybacking component 116 can comprise a third portion 126 adjoining thefirst portion 122 of the primary backing component 116. In theseaspects, the first, second, and third portions 122, 124, 126 of theprimary backing component 116 can extend along respective portions ofthe length 112 of the floor covering 100 such that the first portion 122can be positioned between the second and third portions 124, 126relative to the length 112 of the floor covering 100. The first surface134 of the adhesive layer 132 can be applied to the back surfaces 120 ofthe first, second, and third portions 122, 124, 126 of the primarybacking component 116. The portions of the adhesive layer 132 applied tothe second and third portions 124, 126 of the primary hacking component116 and the second and third portions 124, 126 of the primary backingcomponent 116 can cooperate to define respective first and secondmoveable bodies 140, 144. The secondary backing material 150 can furthercomprise a second exposable portion 156. The second moveable body 144can be unattached to and configured to overlie the second exposableportion 156 of the secondary backing material 150. The second exposableportion 156 can define a portion of the second end edge 108 of the floorcovering 100. The second moveable body 144 can be selectively moveablerelative to the first portion 122 of the primary backing component 116to a position in which at least a portion of the second surface 136 ofthe adhesive layer 132 of the second moveable body 144 can be verticallyspaced from the second exposable portion 156 of the secondary backingmaterial 150.

As disclosed herein, the floor covering 100 can comprise a sealingmaterial 160 disposed onto the second surface 136 of the adhesive layer132 of the moveable body 140. Optionally, in exemplary aspects havingfirst and second moveable bodies 140, 142, the sealing material 160 canbe disposed onto the second surfaces 136 of the adhesive layer 132applied to first and second moveable bodies. In these aspects, thesealing material 160 can be configured to create a barrier between theadhesive layer 132 of the first and second moveable bodies 140, 144 andthe first and second exposable portions 154, 156 of the secondarybacking material 150.

It is contemplated that the second moveable body can be configured forselective pivotal movement relative to the first portion 122 of theprimary backing component 116 such that the second moveable body 144 canbe moveable about and between a closed position and an open position. Inthe closed position, the second moveable body 144 can overlie the secondexposable portion 156 of the secondary backing material 150 and cancooperate with the second exposable portion 156 to define the second endedge 108 of the floor covering 100. In further aspects, the secondmoveable body can be configured to pivot about a pivot axis 168 definedat an intersection 170 between the first and third portions 122, 126 ofthe primary backing component 116 such that the second moveable body 144can be moveable between the closed position and the open position. It iscontemplated that the pivot axis 168 can be perpendicular to alongitudinal axis 166 of the floor covering 100 extending from the firstend edge 106 to the second end edge 108. In the open position, thesecond moveable body 144 can be advanced (e.g., folded) inwardly towardthe first portion 122 of the primary backing component 166. In the openposition, at least a portion of the second surface 136 of the adhesivelayer 132 of the second moveable body 144 can be vertically spaced fromthe second exposable portion 156 of the secondary backing material 150as further disclosed herein. Optionally, in the open position, thesecond moveable body 144 can be advanced (e.g., folded) inwardly suchthat a portion of the adhesive layer 132 of the second moveable body 144overlies the attached portion 152 of the secondary backing material 150(and does not overlie the second exposable portion 156). In theseaspects, the pivot axis 168 at the intersection 170 of the first andthird portions 122, 126 of the primary backing component 116 can bespaced from the second end edge 108 by a selected distance correspondingto a length of the second moveable body 144.

In exemplary aspects, the primary backing component 116 can comprisepolypropylene, polyethylene terephthalate, polyethylene, or acombination thereof. Optionally, the primary backing component 116comprises polypropylene.

In certain aspects, the primary backing component 116 can comprise apolyolefin, a polyester, a polyamide, or combinations thereof. Theprimary backing component can be woven and non-woven. In certainaspects, the primary backing component can comprise non-woven webs, orspunbonded materials. In some aspects, the primary backing component cancomprise a combination of woven and non-woven materials. In someaspects, the primary backing component can comprise a polyolefinpolymer. Optionally, the polyolefin polymer can comprise polypropylene.In yet other aspects, the primary backing component can be a slit filmpolypropylene sheet such as that sold by Propex or Synthetic Industriesowned by Shaw Industries. In yet further aspects, the primary backingcomponent can comprise polyester. In still further aspect, the primarybacking component can comprise polyamide. In yet further aspects, theprimary backing component can comprise a combination of polyamide andpolyester. In these aspects, the polyamide can be nylon. In additionalaspects, the primary backing can comprise a woven polyethyleneterephthalate (PET). In yet other aspects, the primary backing cancomprise a woven PET having a post-consumer and/or post-industrialcontent.

In some exemplary aspects, the primary backing component 116 can be aspun-bond primary backing component. The spun bond backing can beproduced by depositing extruded, spun filaments onto a collecting beltin a uniform random manner followed by bonding the fibers. The fibersare separated during the web laying process by air jets or electrostaticcharges. The collecting surface is usually perforated to prevent the airstream from deflecting and carrying the fibers in an uncontrolledmanner. Bonding imparts strength and integrity to the web by applyingheated rolls or hot needles to partially melt the polymer and fuse thefibers together. Since molecular orientation increases the meltingpoint, fibers that are not highly drawn can be used as thermal bindingfibers. In some aspect, the spun-bond primary backing component cancomprise a bi-component filament of a sheath-core type. In furtheraspects, the polymeric core component can have a higher melting pointthan the polymeric sheath component. In some aspects, the polymeric corecomponent can comprise polyester, aliphatic polyamides, polyphenyleneoxide and/or co-polymers or blends thereof. Optionally, the polyestercan comprise polyethylene terephthalate, polybutylene terephthalate, orpolyparaphenylene terephthalamide. In some aspects, the polymeric corecan comprise polyethylene terephthalate. In still further aspects, thesheath polymer can comprise a polyamide, polyethylene, or polyester. Insome aspects, the sheath polymer comprises nylon. In still furtheraspects, the sheath-core primary backing component can comprise apolyester as a core component and nylon as a sheath component. Theexemplary sheath-core primary backing component can be commerciallyavailable from Bonar. In yet other aspects, a polyester non-wovenprimary backing can be commercially available from Freudenberg.

Optionally, in exemplary aspects, the greige good 114 can comprise aprecoat layer 130 (not shown) disposed between the back surface 120 ofthe primary backing component 116 and the adhesive layer 132. In theseaspects, the precoat layer 130 can at least partially encapsulate theplurality of fibers 128 of the greige good 114. In some aspects, theprecoat layer 130 can comprise latex. In other aspects, the precoatlayer 130 can comprise SBR latex. In further aspects, the precoat layer130 can comprise VAE latex. In still further aspects, the precoat layer130 can comprise EVA latex. Optionally, in other exemplary aspects, theprecoat layer 130 can comprise an acrylic material.

The disclosed floor covering 100 can further comprise an adhesive layer132 comprising an adhesive composition 138 applied to the back surface120 of the primary backing component 116. As noted above, in someaspects, the back surface 120 of the primary backing component 116 canhave a precoat layer 130 applied thereto such that the adhesivecomposition 138 is applied subsequent to the application of the precoatlayer 130. In other aspects where a precoat layer 130 is not present,the adhesive composition 138 can be applied directly to the back surface120 of the primary backing component 116. The adhesive composition 138can be provided by any means known to one of ordinary skills in the art,including, but not limited to, a dispensing apparatus, an extrusionstation, a sprayer for a liquefied adhesive composition, or a lick rollrotating with a pan, which contains the liquefied adhesive composition.Nip rollers can be heated by any means that are known to those havingordinary skill in the art to which the invention relates.

In exemplary aspects, the adhesive layer can comprise a thermoplasticelastomer. Optionally, the thermoplastic elastomer can be ahomogeneously branched ethylene polymer. Optionally, the thermoplasticelastomer can be a polyethylene elastomer. Optionally, the thermoplasticelastomer can be a polypropylene elastomer. Optionally, thethermoplastic elastomer can be an ethylene methyl acrylate (EMA)elastomer. In one exemplary aspect, the thermoplastic elastomer can beVISTAMAXX™ 6202, which is manufactured by ExxonMobil Chemical Company.In another exemplary aspect, the thermoplastic elastomer can be anAFFINITY™ polyolefin plastomer manufactured by the Dow Chemical Company.In a further exemplary aspect, the thermoplastic elastomer can be anENGAGE™ polyolefin elastomers manufactured by Dupont Dow Elastomers JV.

As further disclosed herein, the floor covering 100 can comprise asecondary backing material 150 having an attached portion 152 and atleast a first exposable portion 154. The attached portion 152 can beadhered to the first portion 122 of the primary backing component 116 bycontact with the second surface 136 of the adhesive layer 132, and thesecond portion 124 of the primary backing component 116 can beunattached to the first exposable portion 154 of the secondary backingmaterial 150. In these aspects, the first exposable portion 154 definesa portion of the first end edge 106 of the floor covering 100. Infurther aspects, the second portion 124 of the primary backing component116 can be selectively moveable relative to the first portion 122 of theprimary backing component 116 to a position in which at least a portionof the second portion 124 of the primary backing component 116 isvertically spaced from the first exposable portion 154 of the secondarybacking material 150.

In exemplary aspects, the secondary backing material 150 can comprise atextured bottom surface. Optionally, in these aspects, the texturedbottom surface can define a structure that is configured to create acoefficient of friction sufficient to permit use of the disclosed floorcoverings in desired applications, including, for example and withoutlimitation, synthetic turf applications (e.g., athletic fields).Optionally, the textured bottom surface can comprise a plurality ofprotrusions or projections that are configured to create such acoefficient of friction. In further aspects, it is contemplated that thetextured bottom surface can be configured to be skid-resistant and/orslip-resistant for a particular application, factoring in the specificmaterial of the textured bottom surface and the material upon which thetextured bottom surface will rest.

As further disclosed herein, in exemplary non-limiting aspects, it iscontemplated that the secondary backing material can comprise amulti-layer secondary backing material. Suitable examples of suchmulti-layer secondary backing materials include textured scrimreinforced geomembranes, such as the DURA♦SKRIM® J25DT1 and J30DT1materials manufactured by Raven Industries, Inc.

In exemplary aspects, the secondary backing material can comprisepolypropylene, polyethylene terephthalate, polyethylene, or combinationsthereof. Optionally, the secondary backing material can comprisepolyethylene.

In exemplary aspects, the secondary backing material can comprise awoven material, a non-woven material, or a combination thereof.

Optionally, the secondary backing can comprise a woven material. In oneaspect, the secondary backing can comprise a tape-tape yarn typebacking, or a tape-spun yarn type backing. In certain aspects, thesecondary backing is a tape-tape yarn woven material. In some aspects,the secondary backing comprises a polyolefin. In a yet further aspect,the polyolefin can comprise polypropylene. In certain exemplary aspects,the material for the secondary backing material can be a conventionalmaterial, for example and without limitation, a woven polypropylenefabric sold by Propex. Such exemplary secondary backings can alsocomprise a material that is a leno weave with polypropylene tape runningin one direction and polypropylene spun yarn running in the other. Instill other aspects, the secondary backing material used with thepresent invention is a woven polypropylene fabric with monofilamentsrunning in both directions. A suitable example of such a material ismanufactured by Shaw Industries, Inc. under the designation Style S8880.

In further aspects, the secondary backing material can be a materialknown as a fiber lock weave or “FLW.” FLW is a fabric which includesfibers needle punched into it. It is contemplated that an FLW typefabric can also be used as a primary backing component, for example, ina floor covering with a relatively low pile height or weight.

In some aspects, the secondary backing can be a woven needle punchedpolypropylene fabric such as SoftBac® manufactured by Shaw Industries,Inc. In these aspects, this material has been enhanced by having about1.5 ounce/sq. yard of polypropylene fibers or polyethylene terephthalatefibers needle punched onto one side of it and has a total basis weightof about 3.5 ounce/sq. yard. This needle punched fabric can be laminatedso as to have the polypropylene fibers embedded within the adhesivebacking layer. In still further aspects other materials can be used forthe secondary backing, for example, and without limitation, if anintegral pad is desired, a polyurethane foam or other cushion materialcan be laminated to the back side of the floor covering.

Optionally, the secondary backing can comprise a non-woven material. Incertain aspects, the secondary backing can comprise a spunbond non-wovenmaterial. The spunbond backing can be produced by depositing extruded,spun filaments onto a collecting belt in a uniform random mannerfollowed by bonding the fibers. The fibers can be separated during theweb laying process by air jets or electrostatic charges. The collectingsurface is usually perforated to prevent the air stream from deflectingand carrying the fibers in an uncontrolled manner. Bonding impartsstrength and integrity to the web by applying heated rolls or hotneedles to partially melt the polymer and fuse the fibers together.Since molecular orientation increases the melting point, fibers that arenot highly drawn can be used as thermal binding fibers. In some aspect,the spun-bond secondary backing component can comprise a bi-componentfilament of a sheath-core type. In some aspects, the polymeric corecomponent can have a higher melting point than the polymeric sheathcomponent. In some aspects, the polymeric core component can comprisepolyester, aliphatic polyamides, polyphenylene oxide and/or co-polymersor blends thereof. In yet other aspects, the polyester can comprisepolyethylene terephthalate, polybutylene terephthalate, orpolyparaphenylene terephthalamide. Optionally, in some aspects, thepolymeric core can comprise polyethylene terephthalate. In furtheraspects, the sheath polymer can comprise a polyamide, polyethylene, orpolyester. In yet further aspects, the sheath polymer can comprisenylon. In still further aspects, the sheath-core primary backingcomponent can comprise a polyester as a core component and nylon as asheath component. The exemplary sheath-core secondary backing componentcan be commercially available from Bonar. In yet other aspects, apolyester non-woven secondary backing can be commercially available fromFreudenberg.

In some aspects, the secondary backing material can comprise athermoplastic polyolefin. In certain aspects, the secondary backingmaterial can comprise substantially linear ethylene polymers andhomogeneously branched linear ethylene polymers (i.e., homogeneouslybranched ethylene polymers). Homogeneously branched ethylene polymers(including substantially linear ethylene polymers in particular) havelow solidification temperatures, good adhesion to polypropylene, and lowmodulus relative to conventional ethylene polymers such as low densitypolyethylene (LDPE), heterogeneously branched linear low densitypolyethylene (LLDPE), high density polyethylene (HDPE), andheterogeneously branched ultra low density polyethylene (ULDPE).

In further aspects, when properly selected substantially linear ethylenepolymers or homogeneously branched linear ethylene polymers are used asthe secondary backing materials, the low flexural modulus of thesepolymers offers advantages in ease of floor covering installation andgeneral floor covering handling. Substantially linear ethylene polymers,in particular, when employed as a secondary backing material showenhanced mechanical adhesion to polypropylene which improves theconsolidation and delamination resistance of the various floor coveringlayers and components, i.e., polypropylene fibers, fiber bundles, theprimary backing component. In some aspects, good abrasion resistance isespecially important in commercial floor covering cleaning operations asgood abrasion resistance generally improves floor covering durability.

In additional aspects, the secondary backing material can comprising asubstantially linear ethylene polymer or homogeneously branched linearethylene polymer can provide a substantial fluid and particle barrierwhich enhances the hygienic properties of floor covering. In furtheraspects, use of the secondary backing material comprising asubstantially linear ethylene polymer or homogeneously branched linearethylene polymer can allow totally recyclable floor covering productsparticularly where the floor covering comprises polypropylene fibers.

In some exemplary aspects, the secondary backing material can comprise ahomogeneously branched ethylene polymer. The homogeneously branchedethylene polymer can have a single melting peak between −30° C. and 150°C., as determined using differential scanning calorimetry. In someaspects, the homogeneously branched ethylene polymer used in thesecondary backing material of the disclosed invention, can be asubstantially linear ethylene polymer characterized as having (a) a meltflow ratio, I₁₀/I₂>5.63; (b) a molecular weight distribution,M_(w)/M_(n), as determined by gel permeation chromatography and definedby the equation: (M_(w)/M_(n))<(I₁₀/I₂)−4.63; (c) a gas extrusionrheology such that the critical shear rate at onset of surface meltfracture for the substantially linear ethylene polymer is at least 50percent greater than the critical shear rate at the onset of surfacemelt fracture for a linear ethylene polymer, wherein the linear ethylenepolymer has a homogeneously branched short chain branching distributionand no long chain branching, and wherein the substantially linearethylene polymer and the linear ethylene polymer are simultaneouslyethylene homopolymers or interpolymers of ethylene and at least oneC₃-C₂₀ α-olefin and have the same I₂ and M_(W)/M_(n) and wherein therespective critical shear rates of the substantially linear ethylenepolymer and the linear ethylene polymer are measured at the same melttemperature using a gas extrusion rheometer; and (d) a singledifferential scanning calorimetry, DSC, melting peak between −30° and150° C.

In further aspects, the molecular weight distribution (M_(w)/M_(n)) forthe substantially linear ethylene polymers and homogeneous linearethylene polymers used in the present invention can generally range fromabout 1.8 to about 2.8. Substantially linear ethylene polymers are knownto have excellent processability, despite having a relatively narrowmolecular weight distribution. Unlike homogeneously and heterogeneouslybranched linear ethylene polymers, the melt flow ratio (I₁₀/I₂) ofsubstantially linear ethylene polymers can be varied essentiallyindependently of their molecular weight distribution, M_(w)/M_(n).

In some aspects, the secondary backing material comprising homogeneouslybranched ethylene polymers can include interpolymers of ethylene and atleast one α-olefin prepared by a solution, gas phase, or slurrypolymerization process, or combinations thereof. In some aspects theα-olefins are represented by the following formula:CH₂═CHR

where R is a hydrocarbyl radical. Further, R can be a hydro-carbylradical having from one to twenty carbon atoms and as such the formulaincludes C₃-C₂₀ α-olefins. In other aspects, α-olefins for use ascomonomers include propylene, 1-butene, 1-isobutylene, 1-pentene,1-hexene, 4-methyl-1-pentene, 1-heptene and 1-octene, as well as othercomonomer types such as styrene, halo- or alkyl-substituted styrenes,tetrafluoro-ethylene, vinyl benzocyclobutene, 1,4-hexadiene,1,7-octadiene, and cycloalkenes, e.g., cyclopentene, cyclo-hexene andcyclooctene. In certain aspects, the comonomer will be 1-butene,1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, ormixtures thereof, as secondary backing materials comprised of higherα-olefins will have especially improved toughness. In yet other aspects,the comonomer can be 1-octene and the ethylene polymer can be preparedin a solution process.

In certain aspects, the density of the substantially linear ethylenepolymer or homogeneously branched linear ethylene polymer, as measuredin accordance with ASTM D-792, does not exceed about 0.92 g/cc, and isgenerally in the range from about 0.85 g/cc to about 0.92 g/cc, fromabout 0.86 g/cc to about 0.91 g/cc, and from about 0.86 g/cc to about0.90 g/cc.

In yet further aspects, the molecular weight of the homogeneouslybranched linear ethylene polymer or substantially linear ethylenepolymer can be characterized using a melt index measurement according toASTM D-1238, Condition 190° C./2.16 kg (formerly known as “Condition(E)” and also known as I₂). Melt index is inversely proportional to themolecular weight of the polymer. Thus, the higher the molecular weight,the lower the melt index, although the relationship is not linear. Themelt index for the homogeneously branched linear ethylene polymer orsubstantially linear ethylene polymer is generally from about 1 grams/10minutes (g/10 min) to about 500 g/10 min, about 2 g/10 min to about 300g/10 min, from about 5 g/10 min to about 100 g/10 min, from about 10g/10 min to about 50 g/10 min, and about 25 to about 35 g/10 min.

In some other aspects, an additional measurement can be useful incharacterizing the molecular weight of the homogeneous linear ethylenepolymer or the substantially linear ethylene polymer and can beperformed using a melt index measurement according to ASTM D-1238,Condition 190° C./10 kg (formerly known as “Condition (N)” and alsoknown as I₁₀). The ratio of the ho and the I₂ melt index terms is themelt flow ratio and is designated as I₁₀/I₂. For the substantiallylinear ethylene polymer, the I₁₀/I₂ ratio indicates the degree of longchain branching, i.e., the higher the I₁₀/I₂ ratio, the more long chainbranching in the polymer. The I₁₀/I₂ ratio of the substantially linearethylene polymer is at least about 6.5, at least about 7, or at leastabout 8. The I₁₀/I₂ ratio of the homogeneously branched linear ethylenepolymer is generally less than about 6.3.

In some aspects, the ethylene polymers can have a relative low modulus.That is, the ethylene polymer can be characterized as having a 2% secantmodulus less than about 24,000 psi (163.3 MPa), less than about 19,000psi (129.3 MPa), and less than about 14,000 psi (95.2 MPa), as measuredin accordance with ASTM D790.

In certain aspects, the ethylene polymers described herein can besubstantially amorphous or totally amorphous. That is, the ethylenepolymer can be characterized as having a percent crystallinity less thanabout 40 percent, less than about 30 percent, more less than about 20,and less than about 10 percent, as measured by differential scanningcalorimetry using the equation:percent crystallinity %=(H _(f)/292)×100, where H _(f) is the heat offusion in Joules/gram.

In other aspects, the homogeneously branched ethylene polymer (HBEP) canbe used alone or can be blended or mixed with one or more synthetic ornatural polymeric material. In some aspects, the polymers for blendingor mixing with homogeneously branched ethylene polymers used in thepresent invention include, but are not limited to, another homogeneouslybranched ethylene polymer, low density polyethylene, heterogeneouslybranched LLDPE, heterogeneously branched ULDPE, medium densitypolyethylene, high density polyethylene, grafted polyethylene (e.g. amaleic anhydride extrusion grafted heterogeneously branched linear lowpolyethylene or a maleic anhydride extrusion grafted homogeneouslybranched ultra low density polyethylene), ethylene acrylic acidcopolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylatecopolymer, polystyrene, polypropylene, polyester, polyurethane,polybutylene, polyamide, polycarbonate, rubbers, ethylene propylenepolymers, ethylene styrene polymers, styrene block copolymers, andvulcanates.

In further aspects, the secondary backing material can comprise a blendof at least two polyethylenes, wherein the polyethylene can comprise ahomogeneously branched ethylene polymer (HBEP) or a substantially linearethylene polymer (SLEP), or mixtures thereof. In other aspects, thesecondary backing material can comprise a blend of at least three orfour, or more polyethylenes, wherein the polyethylenes comprise ahomogeneously branched ethylene polymer (HBEP) or a substantially linearethylene polymer (SLEP), or mixtures thereof. Still further, thesecondary backing material can comprise a polyethylene comprising atleast about 80% by weight of at least one (or two or more) HBEP or SLEPas measured by weight of the polyethylene, including exemplary values ofabout 85, 90, 95, 97, 98, or about 99% by weight of the polyethylene,where any value can comprise an upper or a lower endpoint, asappropriate.

In the aspects, where the blend of at least two (or three or more)polyethylenes is used, the amount of each polyethylene can beindividually varied in the amounts of, for example, from about 1, 5, 10,15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 97or about 98% by weight of the total blend, where any value can be usedfor the individual components, and any value can be used as an upper ora lower endpoint, as appropriate.

The density of the polyethylene components in the blend can be fromabout 0.860, 0.870, 0.880, 0.885, 0.890, 0.895, 0.900, 0.905, or about0.910 g/cc, where any value can comprise an upper or a lower endpoint,as appropriate.

The actual blending or mixing of various polymers can be convenientlyaccomplished by any technique known in the art including, but notlimited to, melt extrusion compounding, dry blending, roll milling, meltmixing such as in a Banbury mixer and multiple reactor polymerization.In some aspects, the blends or mixtures can include a homogeneouslybranched ethylene polymer and a heterogeneously branched ethyleneα-olefin interpolymer, wherein the α-olefin is a C₃-C₈ α-olefin preparedusing two reactors operated in parallel or in series with differentcatalyst systems employed in each reactor. Multiple reactorpolymerizations are described in copending applications U.S. Ser. No.08/544,497, filed Oct. 18, 1995 and U.S. Ser. No. 08/327,156, filed Oct.21, 1994, the disclosures of all three of which are incorporated hereinby reference. In some aspects, multiple reactor polymerizations comprisenon-adiabatic solution loop reactors as described in provisionalapplications U.S. Ser. No. 60/014,696 and U.S. Ser. No. 60/014,705, bothfiled Apr. 1, 1996, the disclosures of all of which are incorporatedherein by reference.

In another aspect, the secondary backing material can comprise amodified homogeneously branched ethylene polymer. In particular, incertain aspects of the invention the at least one homogeneously branchedethylene polymer that can be present within the secondary backingmaterial can be modified by the addition of at least one adhesivepolymeric additive. Suitable adhesive polymeric additives include, forexample and without limitation, polymer products comprised of (1) one ormore ethylenically unsaturated carboxylic acids, anhydrides, alkylesters and half esters, e.g., acrylic acid, methacrylic acid, maleicacid, maleic anhydride, itaconic acid, fumaric acid, crotonic acid andcitraconic acid, citraconic anhydride, succinnic acid, succinnicanhydride, methyl hydrogen maleate, and ethyl hydrogen maleate; estersof ethylenically unsaturated carboxylic acids, e.g., ethyl acrylate,methyl methacrylate, ethyl methacrylate, methyl acrylate, isobutylacrylate, and methyl fumarate; unsaturated esters of carboxylic acids,e.g., vinyl acetate, vinyl propionate, and vinyl benzoate; andethylenically unsaturated amides and nitriles e.g., acrylamide,acrylonitrile, methacrylonitrile and fumaronitrile; and (2) one or moreethylenically unsaturated hydrocarbon monomers such as aliphaticα-olefin monomers, e.g., ethylene, propylene, butene-1 and isobutene;conjugated dienes, e.g., butadiene and isoprene; and monovinylidenearomatic carbocyclic monomers, e.g., styrene, α-methylstyrene, toluene,and t-butylstyrene.

A modified homogeneously branched ethylene polymer for use in thesecondary backing materials can be conveniently prepared by knowntechniques such as, for example, by interpolymerization or by apolymerization procedure followed by a chemical or extrusion graftingprocedure. Suitable grafting techniques are described in U.S. Pat. Nos.4,762,890; 4,927,888; 4,230,830; 3,873,643; and 3,882,194, thedisclosures of all of which are incorporated herein by reference.

In some aspects, the adhesive polymeric additives for use in the presentinvention can include maleic anhydride grafts wherein maleic anhydrideis grafted onto an ethylene polymer at a concentration of about 0.1 toabout 5.0 weight percent, about 0.5 to about 1.5 weight percent. Thepresence of ethylene polymer/maleic anhydride grafts as adhesivepolymeric additives in the present invention can improve the performanceand operating window of extrusion coated homogeneously branched ethylenepolymers as the secondary backing material, especially when used inconnection with polar polymers such as for example, but is not limitedto, nylon and polyester faced floor coverings. The improvement pertainedto substantially higher comparative abrasion resistance and tuft bindstrength. In an exemplary aspect, a composition for forming a maleicanhydride graft is the Amplify® GR 204 available from Dow Chemicals.

In further aspects, the ethylene polymers for use as the grafted hostpolymer include low density polyethylene (LDPE), high densitypolyethylene (HDPE), heterogeneously branched linear low densitypolyethylene (LLDPE), homogeneously branched linear ethylene polymersand substantially linear ethylene polymers. In some aspects, the hostethylene polymers have a polymer density greater than or equal to about0.86 g/cc, 0.87 g/cc, 0.88 g/cc, 0.89 g/cc, 0.90 g/cc, 0.91 g/cc, 0.92g/cc, 0.93 g/cc, or greater than or equal to about 0.94 g/cc. In yetother aspects, the substantially linear ethylene polymers and highdensity polyethylene are utilized as host ethylene polymers.

In some aspects, it is contemplated that the secondary backing materialto be extruded or applied by any other technique known in the art. Insome aspects, the secondary backing material of this invention mayoptionally include exemplary additives such as foaming agents, pHcontrollers, flame retardants, fillers, tackifiers, wetting agents,dispersing agents, anti-microbial agents, lubricants, dyes,anti-oxidants, and the like, which are well known to those skilled inthe art, without loss of the characteristic properties.

In one aspect, the secondary backing material can further comprise oneor more flame retardants sufficient to ensure the floor coveringstructure satisfies the requirements of the radiant flux floor coveringtest according to the ASTM-E648 testing procedures. In particular,according to certain aspects, the floor covering of the presentinvention exhibit a Class 1 critical radiant flux of greater than 0.45watts per cm² as measured according to ASTM-E648. According to otheraspects of the invention, the floor covering described herein canexhibit a Class 2 critical radiant flux in the range of from 0.22 to0.44 watts per cm² as measured according to ASTM-E648. In still furtheraspects, the floor covering of the present invention can exhibit anunclassifiable critical radiant flux of less than 0.22 watts per cm² asmeasured according to ASTM-E648.

Exemplary flame retardants that can be incorporated into the secondarybacking materials of the present invention include, without limitation,organo-phosphorous flame retardants, red phosphorous magnesiumhydroxide, magnesium dihydroxide, hexabromocyclododecane, brominecontaining flame retardants, brominated aromatic flame retardants,melamine cyanurate, melamine polyphosphate, melamine borate, methyloland its derivatives, silicon dioxide, calcium carbonate, resourcinolbis-(diphenyl phosphate), brominated latex base, antimony trioxide,strontium borate, strontium phosphate, monomeric N-alkoxy hindered amine(NOR HAS), triazine and its derivatives, high aspect ratio talc,phosphated esters, organically modified nanoclays and nanotubes,non-organically modified nanoclays and nanotubes, ammoniumpolyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates,isopropylated triphenyl phosphate, phosphate esters, magnesiumhydroxide, zinc borate, bentonite (alkaline activated nanoclay andnanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide,diazenedicarboxamide, azodicarbonic acid diamide (ADC), triarylphosphates, isopropylated triphenyl phosphate, triazine derivatives,alkaline activated organoclay and aluminum oxide. Any desired amount offlame retardant can be used in the secondary backing material of theinstant invention and the selection of such amount will depend, in part,upon the particular flame retardant used and desired floor coveringapplications. Such amounts can be readily determined through no morethan routine experimentation.

Exemplary and non-limiting fillers that can be incorporated into thesecondary backing materials of the present invention can include calciumcarbonate, fly-ash, recycled calcium carbonate, aluminum trihydrate,talc, nano-clay, barium sulfate, barite, barite glass fiber, glasspowder, glass cullet, metal powder, alumina, hydrated alumina, clay,magnesium carbonate, calcium sulfate, silica, glass, fumed silica,carbon black, graphite, cement dust, feldspar, nepheline, magnesiumoxide, zinc oxide, aluminum silicate, calcium silicate, titaniumdioxide, titanates, glass microspheres, chalk, calcium oxide, and anycombination thereof. In one aspect, the secondary backing materialcomprises inorganic filler with high heat content. In some aspects, itis for the filler to exhibit relatively high heat content. Examples ofsuch fillers include, but are not limited to, calcium carbonate,aluminum trihydrate, talc, and barite. The exemplified high heat contentfillers allow the extrudate to remain at elevated temperatures longerwith the beneficial result of providing enhanced encapsulation andpenetration. In this aspect, the high heat content fillers should beground or precipitated to a size that can be conveniently incorporatedin an extrusion coating melt stream. Exemplary non-limiting particlesizes for the inorganic filler material can include particle sizes inthe range of from about 1 to about 50 microns. Still further, it shouldalso be understood that the filler component can be present in anydesired amount. However, in an exemplary aspect, the filler is presentin an amount in the range of from about 10 weight % to about 90 weight%, based upon the total weight of the secondary backing material,including exemplary amounts of about 15 weight %, 20 weight %, 25 weight%, 30 weight %, 35 weight %, 40 weight %, 45 weight %, 50 weight %, 55weight %, 60 weight %, 65 weight %, 70 weight %, 75 weight %, 80 weight%, and about 85 weight %. Still further, the amount of filler presentcan be in any range derived from any two of the above stated weightpercentages.

In still another aspect, the secondary backing material can furthercomprise one or more tackifying additives. The tackifier can for examplebe tall oil or rosin based or, alternatively, can be an aliphatic oraliphatic aromatic hydrocarbon blend resin. As the tackifier is anoptional component, the amount of tackifier can be, when present, in therange of from greater than 0 weight percent up to and even exceedingabout 50 weight % of the secondary backing material. For example, in oneaspect, the amount of tackifier can be in the range of from about 5weight % to about 45 weight %. In still another aspect, the amount oftackifier can be in the range of from about 10 weight % to about 20weight %.

As further disclosed herein, the floor covering can comprise a polymerfilm. In exemplary aspects, the polymer film can be applied to a surfaceof the secondary backing material. Optionally, the polymer film can belaminated to the secondary backing material. Optionally, the polymerfilm can be applied to a surface of a second secondary backing material,or laminated to the second secondary backing material. Alternatively,the polymer film can be applied directly to the second surface of theadhesive layer.

In some exemplary aspects, the polymer film can comprise a thermoplasticmaterial. Optionally, the polymer film can be a thermoplastic film. Infurther aspects, the polymer film can comprise polymers and copolymersof polyethylene, polypropylene, polyurethane, polyester,polyvinylchloride, nylon and polyethylene vinyl acetate. Optionally, thepolymer film can comprise polyethylene, polypropylene, polyurethane,polyester, or polyvinylchloride, or a combination thereof. Optionally,the polymer film can be polyethylene. In further aspects, the polymerfilm can be a combination of polyethylene and polyester.

In further aspects, the polymer film can be an extruded film. In otheraspects, the polymer film can be a blown film. In further aspects, thepolymer film can be a cast film. In still further aspects, the polymerfilm can be an engineered film. The term “engineered film” as usedherein refers to a polymer film comprising same or different polymersand copolymers, wherein the film can be formed by various techniques toensure desirable properties. In some aspects, the engineered film can bea reinforced film. In further aspects, and without limitation, theengineered reinforced film can comprise a plurality of layers of thesame or different polymer or copolymer. In other aspects, the engineeredfilm can comprise layers of polyethylene film sandwiched with a layer ofpolyester. In yet further aspects, the engineered film can compriselayers of polyethylene and polypropylene, or layers of polyethylene andchemically resistant ethylene vinyl alcohol (EVOH) copolymer. In certainaspects, the engineered film used in the current disclosure can bepurchased from Raven Industries.

In still further aspects, the polymer film can be a composite film. Thecomposite film can comprise polyethylene and polypropylene. The polymerfilm can comprise a polypropylene core. Optionally, it is contemplatedthat the polymer composite film can comprise at least two layers.Alternatively, in other aspects, the polymer composite film can compriseat least three layers. It is understood that each layer of the polymercomposite film can be the same or different and can comprise any of thepolymers listed above. In some aspects, the composite film can compriseat least three layers, and each outer layer of the composite film cancomprise polyethylene.

In exemplary aspects, the polymer film disclosed herein can act as afluid barrier. In these aspects, the polymer film can be fluidimpermeable. In one aspect, the polymer film can be impermeable toaqueous fluids. In another aspect, the polymer film can be impermeableto non-aqueous fluids. In this aspect, the non-aqueous fluid can be anorganic fluid. In further exemplary aspects, the polymer film can beimpermeable to water, carbonate and non-carbonate beverages, juices,milk, wine, or any other alcohol substances, human or pet bodily fluids,food fluids, food processing fluids, rain, or snow.

In further exemplary aspects, the polymer film can be impermeable togases. For example and without limitation, the polymer film can beimpermeable to volatile organic compounds (VOCs), methane, carbondioxide, carbon oxide, radon, gasoline, benzene and the like. In furtheraspects, the polymer film can be impermeable to the vapors. Optionally,in some exemplary aspects, the polymer film can be a semipermeablematerial. In these aspects, the polymer film can be semipermeable togases. In further aspects, the polymer film can be semipermeable to allatmospheric gases. For example and without limitation, the polymer filmcan be semipermeable to oxygen, hydrogen, carbon dioxide, carbon oxide,nitrogen, and the like.

As disclosed herein, in some aspects, the polymer film can have athickness of less than about 6 mils. In other aspects, the polymer filmcan have a thickness of exemplary values of about 5.5 mils, about 5mils, about 4.5 mils, about 4 mils, about 3.5 mils, about 3 mils, about2.5 mils, about 2 mils, about 1.5 mils, about 1 mil, and about 0.5 mils.In other aspects, the polymer film can have a thickness in any rangederived from any two of the above stated values. For example and withoutlimitation, the polymer film can have a thickness from about 1 mil toabout 5.5 mils, or from about 2 mils to about 4 mils, or from about 1mil to about 3.5 mils.

In other aspects, the polymer film can have a thickness of greater thanabout 10 mils. For example and without limitation, the polymer film canhave a thickness of exemplary values of about 10 mils, about 15 mils,about 20 mils, about 25 mils, about 30 mils, about 35 mils, about 40mils, about 45 mils, about 50 mils, about 55 mil, about 60 mils, about65 mils, about 70 mils, about 75 mils, about 80 mils, about 85 mils,about 90 mils, and about 100 mils. It is contemplated that the polymerfilm can have a thickness in any range derived from any two of the abovestated values. For example and without limitation, the polymer film canhave thickness from about 10 mils to about 40 mils, or from about 30mils to about 50 mils, or from about 30 mil to about 80 mils.

In some aspects, the polymer film can be continuous. In further aspects,the polymer film can be substantially free of perforations or pinholes.Optionally, the polymer film can be continuous and substantially free ofperforations.

In exemplary aspects, the floor covering 100 disclosed herein can be acarpet tile, a broadloom carpet, an area rug, or a synthetic turf floorcovering.

B. Synthetic Turf Floor Coverings

As described herein, in some exemplary aspects, the floor covering 100can be a synthetic turf floor covering. In these exemplary aspects, theplurality of fibers 128 of the greige good 114 can be synthetic turffibers. For example and without limitation, the floor covering 100 canbe a turf floor covering, and the plurality of fibers 128 of the turffloor covering can be synthetic turf fibers.

In further exemplary aspects, the synthetic turf can have a primarybacking layer and a plurality of rows of individual tufts tufted intothe backing layer. Each tuft can comprise at least one yarn per tuft. Itis contemplated that each one of the at least one yarn can vary from theothers in at least one of material, color, texture, tuft denier, denierper filament, cross-section and the like. Alternatively, each one of theat least one yarn can be the same in material, color, texture, tuftdenier, denier per filament, cross-section and the like. Additionally,in some exemplary aspects, the synthetic turf can be unfilled oruninstalled synthetic turf.

In other exemplary aspects, one of the at least one yarns can comprise awrap yarn or a bulk continuous fiber (BCF) yarn. Use of a BCF fiber, ascontemplated herein can avoid the expense of twisting by utilizing awrap yarn to hold multiple filaments together. (However, one skilled inthe art will appreciate that use of twisting is also contemplated withinthe scope of the present disclosure.) In one aspect, the wrap yarn cancomprise one of a low-bulk, low temperature-shrinkage fiber; amedium-bulk, low temperature-shrinkage fiber; and a high-bulk, lowtemperature shrinkage fiber that is configured to shrink down to aselected pile level during the tufting and coating process or subsequentheat treatment. As one skilled in the art will appreciate, havingadditional BCF yarn incorporated into each tuft can enable a greaterdegree of bundle wrap by the coating. In one example, tuft bindincreases of from about 10% to about 20% have been observed due to useof BCF yarn as described above. In one exemplary aspect, yarns havingidentical cross-sections can be selected to differ in their shrinkagerates such that the resultant finished turf comprises tufts havingsmall, medium and large blades. One skilled in the art will appreciatethe range of possible combinations of different yarn characteristicsthat can be achieved herein.

In other exemplary aspects, at least one texturized yarn thread can beutilized in the tuft. It is contemplated that texturized yarn can trapinfill and can desirably reduce infill migration during athletic orother activity. Additionally, it is further contemplated that evenlydistributing the texturized yarn can maximize the benefit of reducedmigration.

In other exemplary aspects, at least one slit tape yarn can be employedin the tuft and, in a further aspect, the slit tape yarn can beconfigured to fold over on the surface. As used herein, the term slittape yarn comprises, for example and without limitation, conventionalslit tape yarn, monofilament slit tape yarn and the like. It iscontemplated that the slit tape yarn can reduce the tendency of rubberinfill to splash when the surface of the synthetic turf is impacted by,for example, a ball, a player or the like. As with texturized yarn, itis contemplated that even distribution of the slit tape yarn willmaximize the benefit of splash reduction.

In other exemplary aspects, at least one monofilament yarn can beemployed in the tuft. It is further contemplated that adjusting orcontrolling the rigidity of the fibers can selectively control the rollof a ball on the surface of the resultant synthetic turf. As thestiffness or rigidity of the monofilament yarn increases, the fibersexhibit increased resistance to the ball and vice-versa. Accordingly, iscontemplated to select a monofilament yarn appropriate to control theroll of a ball according to end use requirements. In a further aspect,it is contemplated that a more even distribution of the monofilamentyarns can ensure a ball will roll evenly in all directions and that evendistribution of monofilament yarns of a selected rigidity or stiffnesscan provide uniform ball roll control.

In other exemplary aspects, the synthetic turf can comprise an infillmaterial disposed on a top surface of the primary backing layer an inbetween the tufts. The infill material can comprise any known infillmaterial such as, for example and without limitation, rubber particles,sand, natural materials and the like.

In other exemplary aspects, each yarn can comprise any cross-sectionknown in the art and, in certain aspects, each yarn can comprise across-section of at least one of a diamond, a rectangle, a serrateddiamond, an oval or otherwise round cross section, a spine, a celery, aserrated celery, a tri-lobal, a winged tri-lobal and the like. Inanother aspect, at least one yarn of the at least one yarns can comprisecross-sections disclosed in U.S. patent application Ser. No. 13/951,133entitled “Yarn Filament for Synthetic Turf and Method for Making theSame and filed on Jul. 25, 2013, and U.S. patent application Ser. No.13/922,967 entitled “Yarn Filament and Method for Making the Same andfiled on Jun. 20, 2013, both of which are hereby incorporated byreference in their respective entireties.

In other exemplary aspects, each yarn can comprise a material selectedfrom the group comprising LDPE, MDPE, Nylon, PP, PET, PLA andco-extruded biomaterials thereof.

In other exemplary aspects, a given tufted row of the plurality oftufted rows is substantially similar to each adjacent tufted row and, ina further aspect, adjacent tufts on a given row are spaced apart at apredetermined gauge. A synthetic turf having a plurality of tufted rowssubstantially similar to each adjacent row can allow a turf installer tocut and install the turf without regard to matching tufted rows. Oneskilled in the art will appreciate that eliminating the need to matchtufted rows can decrease the cost of turf installation by up to about40%.

C. Floor Covering Systems

Referring to FIG. 3 , it is contemplated that the floor covering 100disclosed herein can be used in a floor covering system 200 comprising aplurality of floor coverings 100. In exemplary aspects, the floorcovering system 200 can comprise at least a first and a second floorcovering 100 a, 100 b as described herein. In these exemplary aspects,the first exposable portion 154 of the secondary backing material 150 ofthe first floor covering 100 a can overlie and be welded to the secondexposable portion 156 of the secondary backing material 150 of thesecond floor covering 100 b, thereby forming a continuous, impermeablebarrier 202. In further aspects, no fibers of the plurality of fibers128 are situated between the first exposable portion 154 of thesecondary backing material 150 of the first floor covering 100 a and thesecond exposable portion 156 of the secondary backing material 150 ofthe second floor covering 100 b. In these aspects, the moveable body 140of the first floor covering 100 a can be positioned adjacent to themoveable body 144 of the second floor covering 100 b. Optionally, insome aspects, the moveable body 140 of the first floor covering 100 acan overlie and be secured to the moveable body 144 of the second floorcovering 100 b. Alternatively, in other aspects, the moveable body 144of the second floor covering 100 b can overlie and be secured to themoveable body 140 of the first floor covering 100 a. It is contemplatedthat the floor covering systems 200 disclosed herein can compriseadjacent first and second floor coverings 100 that are capable of beingwelded together such that the pile direction across the adjacent firstand second floor coverings is consistent. In exemplary aspects, eachfloor covering 100 of the floor covering system 200 can be capable offunctioning independently as a floor covering, and the floor coveringsystem comprises a plurality of smaller floor coverings that cooperateto define a larger floor covering.

D. Method of Making Floor Coverings

Also disclosed is a method of making the floor covering describedherein. In exemplary aspects, the adhesive layer can be applied onto aback surface of the primary backing component of at least one greigegood. It is contemplated that the method of making a floor covering cancomprise extruding the adhesive composition onto the back surface of theprimary backing component of the at least one greige good. In furtheraspects, an attached portion of the secondary backing material can belaminated onto the adhesive layer of a first portion of the primarybacking component of the at least one greige good. In these aspects, anexposable portion of the secondary backing material can be unattached toa second portion of the primary backing component that adjoins the firstportion of the primary backing component and at least partially overliesthe exposable portion of the secondary backing material. It iscontemplated that the exposable portion of the secondary backingmaterial can define a portion of an edge of the floor covering.

As further described herein, the second portion of the primary backingcomponent can be pivotally moveable between a closed position and anopen position relative to a pivot axis defined at the intersectionbetween the first and second portions of the primary backing component.Such pivoting capabilities can permit access to the second portion ofthe primary backing component such that the second portion of theprimary backing component can be sealed, as further described herein,thereby creating a barrier between the primary backing component and theexposable portion of the secondary backing material. In these aspects,the second portion of the primary backing component can be pivoted fromthe closed position to the open position to expose at least a portion ofthe exposable portion of the secondary backing material. While thesecond portion of the primary backing component is in the open position,a sealing material can be applied to the second portion of the primarybacking component by contact with the second surface of the portion ofthe adhesive layer applied to the second portion of the primary backingcomponent. Application of the sealing material to the second portion ofthe primary backing component can form a barrier between the secondportion of the primary backing component and the exposable portion ofthe secondary backing material when the second portion of the primarybacking component is in the closed position. Following application ofthe sealing material to the second portion of the primary backingcomponent, the second portion of the primary backing component can bemoved from the open position to the closed position.

FIG. 4 shows an exemplary line 300 for making a floor covering 100 shownin FIGS. 1-2 . As shown in FIG. 4 , a greige good 114 made by attachinga plurality of fibers to the primary backing component 116 and extendingfrom the face surface 118 of the primary backing component 116 areprovided by roll 302, wherein the back surface 120 of the primarybacking component 116 is facing up. The disclosed adhesive layer 132 isapplied to the back surface 120 of the first and second portions 122,124 of the primary backing component 116, or a precoat layer 130, ifpresent. The first portion 122 of the primary backing component 116 isultimately positioned in contact with the attached portion 152 of thesecondary backing material 150, and the second portion 124 of theprimary backing component 116 is ultimately positioned in contact withthe sealing material 160. In this exemplary line, the disclosed sealingmaterial 160 is directed from roll 304, and the disclosed secondarybacking 150 is directed from roll 306. It is contemplated that rotationof roll 304 can be paused, either manually or automatically, whilerotation of rolls 302 and 306 continue such that the sealing material160 is only applied to the second portion 124 of the primary backingcomponent 116. The greige good 114 (with or without the precoat layer),the adhesive layer 132, the sealing material 160, and the secondarybacking material 150 are passed between a set of nip rolls (or pinchrolls) 308 to laminate the attached portion of the secondary backingmaterial 150 and the sealing material 160 to respective portions of thefirst and second portions 122, 124 of the primary backing components116, as described herein.

The adhesive composition can be provided by any means known to one ofordinary skills in the art, including, but not limited to, a dispensingapparatus, an extrusion station, a sprayer for a liquefied adhesivecomposition, or a lick roll rotating with a pan, which contains theliquefied adhesive composition. Nip rollers 308, may be heated by anymeans that are known to those having ordinary skill in the art to whichthe invention relates.

E. Method of Installing

Further disclosed herein, and with reference to FIGS. 5A-5E, are methodsof installing the described floor coverings. In exemplary aspects, themethod of installing can comprise laying down a first floor covering asdescribed herein on a subfloor. In these aspects, the first floorcovering can comprise a secondary backing material having an attachedportion and an exposable portion. As further disclosed herein, theattached portion of the secondary backing material can be adhered to afirst portion of a primary backing component by contact with an adhesivelayer. A moveable body comprising a second portion of the primarybacking component and the portion of the adhesive layer applied to thesecond portion of the primary backing component can adjoin the firstportion of the primary backing component of the first floor covering andcan be unattached from the secondary backing material of the first floorcovering. In these aspects, the moveable body at least partially canoverlie the exposable portion of the secondary backing material of thefirst floor covering. The exposable portion of the secondary backingmaterial can define a portion of a first edge of the first floorcovering.

In further aspects, a second floor covering comprising a secondarybacking material having an attached portion and an exposable portion canbe laid down on the subfloor adjacent to the first floor covering. Aswith the first floor covering, the attached portion can be adhered to afirst portion of a primary backing component by contact with an adhesivelayer. A moveable body comprising a second portion of the primarybacking component and the portion of the adhesive layer applied to thesecond portion of the primary backing component can adjoin the firstportion of the primary backing component of the second floor coveringand can be unattached from the secondary backing material of the secondfloor covering. The moveable body can at least partially overlie theexposable portion of the secondary backing material of the second floorcovering. The exposable portion of the secondary backing material candefine a portion of a first edge of the second floor covering.

In further exemplary aspects, the moveable body of each of the first andsecond floor coverings can be pivotally moveable between a closedposition and an open position relative to a pivot axis defined at theintersection between the first and second portions of the primarybacking components of each respective floor covering. In these aspects,as shown in FIGS. 5A-5B, the moveable bodies can be pivoted from theclosed position to the open position to permit overlapping of theexposable portions of the secondary backing materials of the first andsecond floor coverings. FIG. 5A shows the first and second floorcoverings positioned adjacent to one another, with the moveable bodiessituated in the closed position. Prior to overlapping of the exposableportions of the secondary backing materials, the moveable bodies of thefirst and second floor coverings can be moved to the open position, asshown in FIG. 5B. Each floor covering of the first and second floorcoverings can comprise a plurality of fibers attached to the primarybacking component and extending from a face surface of the primarybacking component. In these aspects, it is contemplated that no fibersof the plurality of fibers of the first and second floor coverings aresituated within the overlapped edge region between the exposableportions of the secondary backing materials of the first and secondfloor coverings.

As shown in FIG. 5C, the exposable portion of the secondary backingmaterial of the first floor covering can be overlapped with theexposable portion of the secondary backing material of the second floorcovering to form an overlapped edge region. Then, the overlapped regionof the first and second floor coverings can be welded together, as shownin FIG. 5D, using conventional methods. To weld the exposable portionsof the secondary backing materials of the first and second floorcoverings together, heat can be applied to the overlapped edge region ofthe first floor covering and the second floor covering.

In exemplary aspects, the step of applying heat can comprise applyingheat and compressive force at the same time to bond the exposableportion of the secondary backing material of the first floor covering tothe exposable portion of the secondary backing material of the secondfloor covering. In further aspects, the step of applying heat can beaccomplished by rolling a heat welder apparatus over the overlapped edgeregion and operating the heat welder apparatus while the head welderapparatus is rolled over the overlapped edge region. As will beappreciated by one skilled in the art, any known conventional heatwelder apparatus can be used to accomplish the step of applying heat tothe overlapped region during the manufacture and/or installationprocesses. For example and without limitation, a wheeled seam welder canbe used. The exemplary seam welder can also include a cabinet and a hotair blower, typically powered by electricity through an electrical cord.The electrical cord can connect the internal circuitry in the cabinetwith the hot air blower. A power cord can connect the internal circuitrywith a source of electric power. It is contemplated that this source ofelectric power can be a portable electric generator. An adjustableupright T-handle can provide a convenient means for guiding the seamwelder. Various controls (such as for surface speed, air temperature,etc.) can be provided on the face of the cabinet.

Following application of heat to the overlapped edge region, themoveable bodies of the first and second floor coverings can be movedfrom the open position to the closed position, as shown in FIG. 5E. Inthe closed position, the moveable body of the first floor covering canbe positioned in contact with (e.g., adjacent to or partiallyoverlapping) the moveable body of the second floor covering. Optionally,the moveable body of the first floor covering can overlie and be securedto the moveable body of the second floor covering. In exemplary aspects,after the moveable bodies are positioned in contact with one another, itis contemplated that the moveable bodies can be spot welded to achieve adesired aesthetic appearance.

In exemplary aspects, it is contemplated that when one end of a floorcovering is positioned adjacent to an outer boundary of a subfloor, suchas a wall, the floor covering will not typically have a moveable body atthe end closest to the outer boundary.

In these aspects, it is contemplated that each floor covering of thefirst and second floor coverings can be a carpet tile, a broadloomcarpet, an area rug, or a synthetic turf floor covering. In furtheraspects, the plurality of fibers of each floor covering can be syntheticturf fibers.

The floor covering system disclosed herein can offer many advantages toone of skill in the art including, for example, ease of heat welding andproper installation of floor coverings. The movability of the moveablebody from the closed position to the open position provides anopportunity to create an improved seam between overlapping regions ofthe secondary backing materials of adjacent floor coverings, therebyproviding a stronger seam and a substantially impermeable barrier.Moreover, because the overlapping region can be welded together whilethe moveable bodies of adjacent floor coverings are held in the openposition, the likelihood of any fibers or tufts becoming positionedbetween the secondary backing materials of the overlapping region issubstantially minimized or eliminated, and the overall size of the weldis significantly reduced compared to conventional methods in which theentire thickness of one floor covering is welded to the entire thicknessof another floor covering. Additionally, the seal at the overlappedregion can be covered by moving the moveable bodies of adjacent floorcoverings to the closed position and, thereby providing a continuous,aesthetically-pleasing appearance.

F. Exemplary Aspects

In view of the described products, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspect 1: A floor covering having opposed first and second side edgesand opposed first and second end edges extending between and orientedperpendicularly to the first and second side edges, the floor coveringhaving a width corresponding to a distance between the first and secondside edges and a length corresponding to a distance between the firstand second end edges, the floor covering comprising: (a) a greige goodcomprising: (i) a primary backing component defining a face surface andan opposed back surface and having a first portion and a second portionadjoining the first portion, wherein the first and second portions ofthe primary backing component extend along respective portions of thelength of the floor covering; and (ii) a plurality of fibers attached tothe primary backing component and extending from the face surface of theprimary backing component; and (b) an adhesive layer having a firstsurface and an opposed second surface and comprising an adhesivecomposition, wherein the first surface of the adhesive layer is appliedto the back surface of the first and second portions of the primarybacking component, wherein the portion of the adhesive layer applied tothe second portion of the primary backing component and the secondportion of the primary backing component cooperate to define a moveablebody; and (c) a secondary backing material having an attached portionand at least a first exposable portion, wherein the attached portion isadhered to the first portion of the primary backing component by contactwith the second surface of the adhesive layer underlying the firstportion of the primary backing component, wherein the moveable body isunattached to the first exposable portion of the secondary backing, andwherein the first exposable portion defines a portion of the first endedge of the floor covering, wherein the moveable body is selectivelymoveable relative to the first portion of the primary backing componentto a position in which at least a portion of the second surface of theadhesive layer of the moveable body is vertically spaced from the firstexposable portion of the secondary backing material.

Aspect 2: The floor covering of aspect 1, further comprising a sealingmaterial disposed onto the second surface of the adhesive layer appliedto the moveable body, wherein the sealing material is configured tocreate a barrier between the adhesive layer of the moveable body and thefirst exposable portion of the secondary backing material.

Aspect 3: The floor covering of aspect 1 or aspect 2, wherein theprimary backing component comprises a plurality of primary backingcomponents.

Aspect 4: The floor covering of any one of aspects 1-3, wherein thesecondary backing material comprises a plurality of secondary backingmaterials.

Aspect 5: The floor covering of any one of aspects 1-4, wherein themoveable body is configured for selective pivotal movement relative tothe first portion of the primary backing component such that themoveable body is moveable about and between a closed position and anopen position, wherein in the closed position, the moveable bodyoverlies the first exposable portion of the secondary backing materialand cooperates with the first exposable portion to define the first endedge of the floor covering.

Aspect 6: The floor covering of aspect 5, wherein the moveable body isconfigured to pivot about a pivot axis defined at an intersectionbetween the first and second portions of the primary backing componentsuch that the moveable body is moveable between the closed position andthe open position, wherein the pivot axis is perpendicular to alongitudinal axis of the floor covering extending from the first endedge to the second end edge.

Aspect 7: The floor covering of aspect 6 or aspect 7, wherein in theopen position, the moveable body is folded inwardly toward the firstportion of the primary backing component, and wherein the pivot axis isspaced from the first end edge by a selected distance corresponding to alength of the moveable body.

Aspect 8: The floor covering of any one of aspects 1-7, wherein theselected distance ranges from about 1 inch to about 25 inches.

Aspect 9: The floor covering of aspect 8, wherein the selected distanceranges from about 5 inches to about 20 inches.

Aspect 10: The floor covering of aspect 9, wherein the selected distanceranges from about 6 inches to about 18 inches.

Aspect 11: The floor covering of any one of aspects 1-10, wherein thegreige good further comprises a precoat layer disposed between the backsurface of the primary backing component and the adhesive layer.

Aspect 12: The floor covering of any one of aspects 1-11, wherein theprimary backing component comprises polypropylene, polyethyleneterephthalate, polyethylene, or combinations thereof.

Aspect 13: The floor covering of aspect 12, wherein the primary backingcomponent comprises polypropylene.

Aspect 14: The floor covering of any one of aspects 1-13, wherein theadhesive composition comprises a thermoplastic elastomer.

Aspect 15: The floor covering of aspect 14, wherein the thermoplasticelastomer is a homogeneously branched ethylene polymer.

Aspect 16: The floor covering of aspect 14, wherein the thermoplasticelastomer is a polyethylene elastomer.

Aspect 17: The floor covering of aspect 14, wherein the thermoplasticelastomer is a polypropylene elastomer.

Aspect 18: The floor covering of aspect 14, wherein the thermoplasticelastomer is an ethylene methyl acrylate (EMA) elastomer.

Aspect 19: The floor covering of any one of aspects 1-18, wherein thesecondary backing material comprises polypropylene, polyethyleneterephthalate, polyethylene, or combinations thereof.

Aspect 20: The floor covering of aspect 19, wherein the secondarybacking material comprises polyethylene.

Aspect 21: The floor covering of any one of aspects 1-20, wherein thesecondary backing material comprises a woven material, a non-wovenmaterial, or a combination thereof.

Aspect 22: The floor covering of any one of aspects 1-21, wherein thesecondary backing material further comprises a polymer film applied to asurface of the secondary backing material.

Aspect 23: The floor covering of aspect 22, wherein the polymer film issubstantially impermeable to fluids.

Aspect 24: The floor covering of aspect 22, wherein the polymer film issubstantially impermeable to gases.

Aspect 25: The floor covering of any one of aspects 22-24, wherein thepolymer film is a thermoplastic film.

Aspect 26: The floor covering of any one of aspects 22-25, wherein thepolymer film is a composite film.

Aspect 27: The floor covering of any one of aspects 22-26, wherein thepolymer film comprises polyethylene, polypropylene, polyurethane,polyester, polyvinylchloride, or a combination thereof.

Aspect 28: The floor covering of aspect 27, wherein the polymer filmcomprises polyethylene.

Aspect 29: The floor covering of aspect 26, wherein the polymer film isa composite film comprising polyethylene and polypropylene.

Aspect 30: The floor covering of aspect 29, wherein the polymer filmcomprises a polypropylene core.

Aspect 31: The floor covering of aspect 26, wherein the polymercomposite film comprises at least three layers, and wherein each outerlayer of the composite film comprises polyethylene.

Aspect 32: The floor covering of any one of aspects 22-31, wherein thepolymer film has a thickness of less than about 6 mils.

Aspect 33: The floor covering of aspect 32, wherein the polymer film hasa thickness of about 2 to about 4 mils.

Aspect 34: The floor covering of any one of aspects 22-33, wherein thepolymer film is an extruded film.

Aspect 35: The floor covering of any one of aspects 22-33, wherein thepolymer film is a blown film.

Aspect 36: The floor covering of any one of aspects 22-33, wherein thepolymer film is a cast film.

Aspect 37: The floor covering of any one of aspects 22-33, wherein thepolymer film is an engineered film.

Aspect 38: The floor covering of any one of aspects 22-37, wherein thepolymer film is continuous and substantially free of perforations.

Aspect 39: The floor covering of any one of aspects 1-38, wherein thefloor covering is a carpet tile, a broadloom carpet, an area rug, or asynthetic turf floor covering.

Aspect 40: The floor covering of any one of aspects 1-38, wherein theplurality of fibers are synthetic turf fibers.

Aspect 41: The floor covering of any one of aspects 1-40, wherein theprimary backing component further comprises a third portion adjoiningthe first portion of the primary backing component, wherein the first,second, and third portions of the primary backing component extend alongrespective portions of the length of the floor covering such that thefirst portion is positioned between the second and third portionsrelative to the length of the floor covering, wherein the first surfaceof the adhesive layer is applied to the back surface of the first,second, and third portions of the primary backing component, wherein theportions of the adhesive layer applied to the second and third portionsof the primary backing component and the second and third portions ofthe primary backing component cooperate to define respective first andsecond moveable bodies, wherein the secondary backing material furthercomprises a second exposable portion, wherein the second moveable bodyis unattached to and configured to overlie the second exposable portionof the secondary backing material, wherein the second exposable portiondefines a portion of the second end edge of the floor covering, andwherein the second moveable body is selectively moveable relative to thefirst portion of the primary backing component to a position in which atleast a portion of the second surface of the adhesive layer of thesecond moveable body is vertically spaced from the second exposableportion of the secondary backing material.

Aspect 42: The floor covering of aspect 41, further comprising a sealingmaterial disposed onto the second surfaces of the adhesive layer appliedto the first and second moveable bodies, wherein the sealing material isconfigured to create a barrier between the adhesive layer of the firstand second moveable bodies and the first and second exposable portionsof the secondary backing material.

Aspect 43: The floor covering of any one of aspects 41-42, wherein thesecond moveable body is configured for selective pivotal movementrelative to the first portion of the primary backing component such thatthe second moveable body is moveable about and between a closed positionand an open position, wherein in the closed position, the secondmoveable body overlies the second exposable portion of the secondarybacking material and cooperates with the second exposable portion todefine the second end edge of the floor covering.

Aspect 44: The floor covering of aspect 43, wherein the second moveablebody is configured to pivot about a pivot axis defined at anintersection between the first and third portions of the primary backingcomponent such that the second moveable body is moveable between theclosed position and the open position, wherein the pivot axis isperpendicular to a longitudinal axis of the floor covering extendingfrom the first end edge to the second end edge.

Aspect 45: The floor covering of aspect 44, wherein in the openposition, the second moveable body is folded inwardly toward the firstportion of the primary backing component, and wherein the pivot axis atthe intersection of the first and third portions of the primary backingis spaced from the second end edge by a selected distance correspondingto a length of the second moveable body.

Aspect 46: A floor covering system, comprising: at least a first and asecond floor covering as recited in any one of claims 1-45, wherein thefirst exposable portion of the secondary backing material of the firstfloor covering overlies and is welded to the second exposable portion ofthe secondary backing material of the second floor covering, therebyforming a continuous, substantially impermeable barrier.

Aspect 47: The floor covering system of aspect 46, wherein no fibers ofthe plurality of fibers are situated between the first exposable portionof the secondary backing material of the first floor covering and thesecond exposable portion of the secondary backing material of the secondfloor covering.

Aspect 48: The floor covering system of any one of aspects 46-47,wherein the moveable body of the first floor covering is positionedadjacent to the moveable body of the second floor covering.

Aspect 49: The floor covering system of any one of aspects 46-47,wherein the moveable body of the first floor covering overlies and issecured to the moveable body of the second floor covering.

Aspect 50: The floor covering system of any one of aspects 46-47,wherein the moveable body of the second floor covering overlies and issecured to the moveable body of the first floor covering.

Aspect 51: A method of making a floor covering, comprising: (a) applyingan adhesive layer onto a back surface of a primary backing component ofat least one greige good, the at least one greige good furthercomprising a plurality of fibers attached to the primary backingcomponent and extending from a face surface of the primary backingcomponent; and (b) laminating an attached portion of the secondarybacking material onto the adhesive layer of a first portion of theprimary backing component of the at least one greige good, wherein anexposable portion of the secondary backing material is unattached to asecond portion of the primary backing component that adjoins the firstportion of the primary backing component and at least partially overliesthe exposable portion of the secondary backing material, wherein theexposable portion of the secondary backing material defines a portion ofan edge of the floor covering.

Aspect 52: The method of making a floor covering of aspect 51, whereinthe second portion of the primary backing component is pivotallymoveable between a closed position and an open position relative to apivot axis defined at the intersection between the first and secondportions of the primary backing component.

Aspect 53: The method of making a floor covering of aspect 52, furthercomprising pivoting the second portion of the primary backing componentfrom the closed position to the open position to expose at least aportion of the exposable portion of the secondary backing material.

Aspect 54: The method of making a floor covering of aspect 53, furthercomprising applying a sealing material to the second portion of theprimary backing component by contact with the second surface of theportion of the adhesive layer applied to the second portion of theprimary backing component, wherein application of the sealing materialto the second portion of the primary backing component forms a barrierbetween the second portion of the primary backing component and theexposable portion of the secondary backing material when the secondportion of the primary backing component is in the closed position.

Aspect 55: The method of making a floor covering of aspect 54, furthercomprising moving the second portion of the primary backing componentfrom the open position to the closed position following application ofthe sealing material to the second portion of the primary backingcomponent.

Aspect 56: A method of installing a floor covering, comprising: (a)laying down a first floor covering on a subfloor, the first floorcovering comprising a secondary backing material having an attachedportion and an exposable portion, wherein the attached portion isadhered to a first portion of a primary backing component by contactwith an adhesive layer, and wherein a second portion of the primarybacking component adjoins the first portion of the primary backingcomponent of the first floor covering and is unattached from thesecondary backing material of the first floor covering, wherein thesecond portion of the primary backing component at least partiallyoverlies the exposable portion of the secondary backing material of thefirst floor covering, and wherein the exposable portion of the secondarybacking material defines a portion of a first edge of the first floorcovering; (b) laying down a second floor covering on the subfloor, thesecond floor covering comprising a secondary backing material having anattached portion and an exposable portion, wherein the attached portionis adhered to a first portion of a primary backing component by contactwith an adhesive layer, and wherein a second portion of the primarybacking component adjoins the first portion of the primary backingcomponent of the second floor covering and is unattached from thesecondary backing material of the second floor covering, wherein thesecond portion of the primary backing component at least partiallyoverlies the exposable portion of the secondary backing material of thesecond floor covering, and wherein the exposable portion of thesecondary backing material defines a portion of a first edge of thesecond floor covering; (c) overlapping the exposable portion of thesecondary backing material of the first floor covering with theexposable portion of the secondary backing material of the second floorcovering to form an overlapped edge region; and (d) applying heat to theoverlapped edge region of the first floor covering and the second floorcovering to weld the exposable portions of the secondary backingmaterials of the first and second floor coverings together.

Aspect 57: The method of installing a floor covering of aspect 56,wherein the second portion of the primary backing component of each ofthe first and second floor coverings is pivotally moveable between aclosed position and an open position relative to a pivot axis defined atthe intersection between the first and second portions of the primarybacking components of each respective floor covering.

Aspect 58: The method of installing a floor covering of aspect 57,further comprising pivoting the second portions of the primary backingcomponent from the closed position to the open position to permitoverlapping of the exposable portions of the secondary backing materialsof the first and second floor coverings.

Aspect 59: The method of installing a floor covering of aspect 58,wherein each floor covering of the first and second floor coveringscomprises a plurality of fibers attached to the primary backingcomponent and extending from a face surface of the primary backingcomponent, and wherein no fibers of the plurality of fibers of the firstand second floor coverings are situated within the overlapped edgeregion between the exposable portions of the secondary backing materialsof the first and second floor coverings.

Aspect 60: The method of installing a floor covering of aspect 59,further comprising moving the second portions of the primary backingcomponents of the first and second floor coverings from the openposition to the closed position following application of heat to theoverlapped edge region.

Aspect 61: The method of installing a floor covering of aspect 60,wherein, in the closed position, the second portion of the primarybacking component of the first floor covering is positioned adjacent tothe second portion of the primary backing component of the second floorcovering.

Aspect 62: The method of installing a floor covering of aspect 61,wherein the second portion of the primary backing component of the firstfloor covering overlies and is secured to the second portion of theprimary backing component of the second floor covering.

Aspect 63: The method of installing a floor covering of any one ofaspects 56-62, wherein the step of applying heat comprises applying heatand compressive force at the same time to bond the exposable portion ofthe secondary backing material of the first floor covering to theexposable portion of the secondary backing material of the second floorcovering.

Aspect 64: The method of installing a floor covering of any one ofaspects 56-63, wherein the step of applying heat is accomplished byrolling a heat welder apparatus over the overlapped edge region andoperating the heat welder apparatus while the head welder apparatus isrolled over the overlapped edge region.

Aspect 65: The method of installing a floor covering of any one ofaspects 56-64, wherein each floor covering of the first and second floorcoverings is a carpet tile, a broadloom carpet, an area rug, or asynthetic turf floor covering.

Aspect 66: The method of installing a floor covering of any one ofaspects 59-65, wherein the plurality of fibers of each floor covetingare synthetic turf fibers.

All publications and patent applications mentioned in the specificationare indicative of the level of those skilled in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated to be incorporated by reference.

Although the foregoing invention has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, certain changes and modifications may be practiced withinthe scope of the appended claims.

What is claimed is:
 1. A floor covering comprising: a primary backingcomponent defining a face surface and an opposed back surface and havinga first portion and a second portion adjoining the first portion,wherein the first and second portions of the primary backing componentextend along respective portions of a length of the floor covering; anda plurality of fibers attached to the primary backing component andextending from the face surface of the primary backing component; anadhesive layer having a first surface and an opposed second surface,wherein the first surface of the adhesive layer is applied to the backsurface of the first and second portions of the primary backingcomponent, wherein the portion of the adhesive layer applied to thesecond portion of the primary backing component and the second portionof the primary backing component cooperate to define a moveable body;and a secondary backing material having an attached portion and at leasta first exposable portion, wherein the attached portion is adhered tothe first portion of the primary backing component by contact with thesecond surface of the adhesive layer underlying the first portion of theprimary backing component, wherein the moveable body is unattached tothe first exposable portion of the secondary backing, wherein themoveable body is selectively pivotally moveable relative to the firstportion of the primary backing component.
 2. The floor covering of claim1, further comprising a sealing material disposed onto the secondsurface of the adhesive layer applied to the moveable body, wherein thesealing material is configured to create a barrier between the adhesivelayer of the moveable body and the first exposable portion of thesecondary backing material.
 3. The floor covering of claim 1, whereinthe moveable body is moveable about and between a closed position and anopen position, wherein in the closed position, the moveable bodyoverlies the first exposable portion of the secondary backing materialand cooperates with the first exposable portion to define a first endedge of the floor covering.
 4. The floor covering of claim 3, whereinthe moveable body is configured to pivot about a pivot axis defined atan intersection between the first and second portions of the primarybacking component such that the moveable body is moveable between theclosed position and the open position, wherein the pivot axis isperpendicular to a longitudinal axis of the floor covering extendingfrom the first end edge to an opposing second end edge, wherein in theopen position, the moveable body is folded inwardly toward the firstportion of the primary backing component, and wherein the pivot axis isspaced from the first end edge by a selected distance corresponding to alength of the moveable body.
 5. The floor covering of claim 1, whereineach of the primary backing component and the secondary backingcomponent comprises polypropylene, polyethylene terephthalate,polyethylene, or combinations thereof.
 6. The floor covering of claim 1,wherein the adhesive layer comprises a thermoplastic elastomer selectedfrom the group consisting of a polyethylene elastomer, a polypropyleneelastomer, and an ethylene methyl acrylate (EMA) elastomer.
 7. The floorcovering of claim 1, wherein the secondary backing material furthercomprises a polymer film, wherein the polymer film is continuous andsubstantially free of perforations, and wherein the polymer film issubstantially impermeable to at least one of fluid or gas.
 8. The floorcovering of claim 7, wherein the polymer film is a thermoplastic film ora composite film and comprises polyethylene, polypropylene,polyurethane, polyester, polyvinylchloride, or a combination thereof. 9.The floor covering of claim 7, wherein the polymer film comprises apolypropylene core.
 10. The floor covering of claim 8, wherein thepolymer composite film comprises at least three layers, and wherein eachouter layer of the composite film comprises polyethylene.
 11. The floorcovering of claim 7, wherein the polymer film is an extruded film, ablown film, a cast film, an engineered film, or combinations thereof.12. The floor covering of claim 1, wherein the plurality of fibers aresynthetic turf fibers.
 13. The floor covering of claim 1, wherein theprimary backing component further comprises a third portion adjoiningthe first portion of the primary backing component, wherein the first,second, and third portions of the primary backing component extend alongrespective portions of the length of the floor covering such that thefirst portion is positioned between the second and third portionsrelative to the length of the floor covering, wherein the first surfaceof the adhesive layer is applied to the back surface of the first,second, and third portions of the primary backing component, wherein theportions of the adhesive layer applied to the second and third portionsof the primary backing component and the second and third portions ofthe primary backing component cooperate to define respective first andsecond moveable bodies, wherein the secondary backing material furthercomprises a second exposable portion, wherein the second moveable bodyis unattached to and configured to overlie the second exposable portionof the secondary backing material, wherein the second exposable portiondefines a portion of a second end edge of the floor covering thatopposes the first end edge, and wherein the second moveable body isselectively pivotally moveable relative to the first portion of theprimary backing component.
 14. The floor covering of claim 13, furthercomprising a sealing material disposed onto the second surfaces of theadhesive layer applied to the first and second moveable bodies, whereinthe sealing material is configured to create a barrier between theadhesive layer of the first and second moveable bodies and the first andsecond exposable portions of the secondary backing material.
 15. Thefloor covering of claim 13, wherein the second moveable body is moveableabout and between a closed position and an open position, wherein in theclosed position, the second moveable body overlies the second exposableportion of the secondary backing material and cooperates with the secondexposable portion to define the second end edge of the floor covering.16. The floor covering of claim 15, wherein the second moveable body isconfigured to pivot about a pivot axis defined at an intersectionbetween the first and third portions of the primary backing componentsuch that the second moveable body is moveable between the closedposition and the open position, wherein the pivot axis is perpendicularto a longitudinal axis of the floor covering extending from the firstend edge to the second end edge.
 17. The floor covering of claim 16,wherein in the open position, the second moveable body is foldedinwardly toward the first portion of the primary backing component, andwherein the pivot axis at the intersection of the first and thirdportions of the primary backing is spaced from the second end edge by aselected distance corresponding to a length of the second moveable body.18. A floor covering system, comprising: at least a first and a secondfloor covering, each floor covering comprising: a primary backingcomponent defining a face surface and an opposed back surface and havinga first portion and a second portion adjoining the first portion,wherein the first and second portions of the primary backing componentextend along respective portions of a length of the floor covering; anda plurality of fibers attached to the primary backing component andextending from the face surface of the primary backing component; anadhesive layer having a first surface and an opposed second surface,wherein the first surface of the adhesive layer is applied to the backsurface of the first and second portions of the primary backingcomponent, wherein the portion of the adhesive layer applied to thesecond portion of the primary backing component and the second portionof the primary backing component cooperate to define a moveable body;and a secondary backing material having an attached portion and at leasta first exposable portion, wherein the attached portion is adhered tothe first portion of the primary backing component by contact with thesecond surface of the adhesive layer underlying the first portion of theprimary backing component, wherein the moveable body is unattached tothe first exposable portion of the secondary backing, wherein themoveable body is selectively pivotally moveable relative to the firstportion of the primary backing component, and wherein the firstexposable portion of the secondary backing material of the first floorcovering overlies and is welded to the first exposable portion of thesecondary backing material of the second floor covering, thereby forminga continuous, substantially impermeable barrier.
 19. The floor coveringsystem of claim 18, wherein no fibers of the plurality of fibers aresituated between the first exposable portion of the secondary backingmaterial of the first floor covering and the first exposable portion ofthe secondary backing material of the second floor covering.
 20. Amethod of installing a floor covering, comprising: (a) laying down afirst floor covering on a subfloor, the first floor covering comprisinga secondary backing material having an attached portion and an exposableportion, wherein the attached portion is adhered to a first portion of aprimary backing component by contact with an adhesive layer, and whereina second portion of the primary backing component adjoins the firstportion of the primary backing component of the first floor covering andis unattached from the secondary backing material of the first floorcovering, wherein the second portion of the primary backing component atleast partially overlies the exposable portion of the secondary backingmaterial of the first floor covering, and wherein the exposable portionof the secondary backing material defines a portion of a first edge ofthe first floor covering; (b) laying down a second floor covering on thesubfloor, the second floor covering comprising a secondary backingmaterial having an attached portion and an exposable portion, whereinthe attached portion is adhered to a first portion of a primary backingcomponent by contact with an adhesive layer, and wherein a secondportion of the primary backing component adjoins the first portion ofthe primary backing component of the second floor covering and isunattached from the secondary backing material of the second floorcovering, wherein the second portion of the primary backing component atleast partially overlies the exposable portion of the secondary backingmaterial of the second floor covering, and wherein the exposable portionof the secondary backing material defines a portion of a first edge ofthe second floor covering; (c) overlapping the exposable portion of thesecondary backing material of the first floor covering with theexposable portion of the secondary backing material of the second floorcovering to form an overlapped edge region; and (d) applying heat to theoverlapped edge region of the first floor covering and the second floorcovering to weld the exposable portions of the secondary backingmaterials of the first and second floor coverings together.